Power contact element with a heat sink and charging connector with at least one such power contact element

Abstract

The invention relates to a contact element (100) for transmitting electrical energy, preferably for a charging connector (1), comprising: a heat sink (200) for receiving and discharging a cooling medium (M), which, in order to form a cooling channel (203) along a longitudinal direction (L) of the contact element (100), encloses a contact element section (102) of the contact element (100) in order to flush the contact element section (102) with the cooling medium (M) within the cooling channel (203); wherein an insulating element (220) with at least one first functional layer (221) is arranged on the contact element section (102) for insulating the contact element section (102), wherein the at least one first functional layer (221) for arranging at least one sealing element (231, 232) for sealing the cooling channel (203) comprises a functional surface (221.1) which is characterized by a defined roughness, wherein preferably the functional surface (221.1) a smooth functional surface (221.1). The invention further relates to a charging connector (1) for transmitting electrical energy and / or electrical signals with at least one contact element (100).

Description

[0001] The present invention lies in the field of electrical energy transmission technology, preferably charging technology, and relates to a contact element for transmitting electrical energy, wherein the contact element comprises a heat sink. The present invention further relates to a charging connector for transmitting electrical energy and / or electrical signals with such a contact element.

[0002] Contact elements for transmitting electrical energy are configured differently depending on their intended use and application, and must meet a variety of requirements. In the field of charging technology for electric vehicles, especially in so-called high-power charging (HPC), contact elements for transmitting electrical energy are used in conjunction with a cooling system. To manage heat generation during the charging process, HPC systems typically use cooling technologies such as liquid-cooled charging connectors and charging cables.

[0003] Liquid-cooled charging connectors utilize different technologies for the interaction between the coolant and the contact elements. For example, the "wet copper" configuration refers to a design where the contact elements are in direct contact with the coolant, whereas the "dry copper" configuration refers to a design where the contact elements are physically separated from the coolant. This physical separation can be achieved, for example, with a heat sink or another material that conducts the generated heat from the contact elements to the coolant. Coolants, especially in directly cooled charging connectors, are typically water-glycol mixtures or oil-based, and should ideally be electrically non-conductive.

[0004] Another aspect in this context is the electrical isolation between the respective potentials (DC+ and DC-) to prevent, for example, leakage current flow. This aims, among other things, to prevent electrolysis and associated effects such as the formation of hydrogen gas or ion migration.

[0005] Various approaches to cooling contact elements are known from the patent literature of the prior art, with reference, for example, to the following publications: DE 10 2022 103 224 A1, DE 10 2020 107 296 A1 and EP 3 103 173 B1.

[0006] It is an object of the present invention to provide a contact element for the transmission of electrical energy, which is characterized by an improved cooling concept. Furthermore, it is an object of the present invention to provide a charging connector with at least one such contact element.

[0007] The problem is solved by the features of claims 1 and 12. Further embodiments and applications of the present invention will become apparent from the dependent claims and are explained in more detail in the following description with partial reference to the figures.

[0008] According to a first general aspect, the present invention relates to a contact element for transmitting electrical energy, preferably for a charging connector, comprising: a heat sink for receiving and discharging a cooling medium, which, in order to form a cooling channel along a longitudinal direction of the contact element, encloses a contact element section of the contact element in order to flush the contact element section with the cooling medium within the cooling channel; wherein, for insulating the contact element section, an insulating element with at least one first functional layer is arranged on the contact element section, wherein the at least one first functional layer for arranging at least one sealing element for sealing the cooling channel comprises a functional surface characterized by a defined roughness, wherein the functional surface is preferably a substantially smooth functional surface.

[0009] The present invention provides a contact element characterized by an improved cooling concept. The heat sink and the insulating element are characterized, for example, by a comparatively simple and / or compact design, while simultaneously ensuring effective cooling of the contact element by means of a cooling medium. The cooling medium is preferably a liquid. The insulating element can be essentially in the form of a tube or a casing. The insulating element can be configured to perform several functions, in particular an insulating function and / or a sealing function. For example, the insulating element can ensure that the cooling medium does not come into contact with the contact element. The contact element can therefore be characterized by a so-called indirect cooling concept.

[0010] The at least one functional surface and its properties enable the formation of a sufficient sealing connection with at least one sealing element. This sealing element can, for example, be an O-ring. The defined roughness of the functional surface can, for example, be in a range between approximately Ra 0.2 µm and approximately Ra 0.8 µm.

[0011] The longitudinal direction is preferably a direction in and / or along which the contact element extends at its longest (maximum) extent.

[0012] In other words, the invention relates to an arrangement comprising a contact element, a heat sink and an insulating element.

[0013] According to a further aspect of the present invention, it can be provided that the at least one first functional layer is formed in the form of a film and / or tube and encases the contact element section in a circumferential direction.

[0014] It is possible that at least one first functional layer is made of a shrinkable material and / or is arranged on the contact element section by a shrinking process, preferably according to the principle of a shrink tube.

[0015] At least one initial functional layer can be an outer layer of the insulating element, which limits and / or defines the cooling channel section by section.

[0016] By forming at least one initial functional layer as heat shrink tubing, sufficient attachment to the contact element section can be ensured.

[0017] According to a further aspect of the present invention, it can be provided that the insulating element comprises at least a second functional layer which is configured for electrical insulation of the contact element section and / or which is configured to form a substantially material-bonded connection, preferably an adhesive bond, with the contact element section.

[0018] The at least one second functional layer can be made of a shape-variable and / or adhesive insulating material with inherent electrical insulating properties and resulting insulating capabilities.

[0019] The insulating element can be characterized by a composite of at least two functional layers.

[0020] It is possible that at least one first functional layer and at least one second functional layer encase the contact element section in a circumferential direction, forming a prestress.

[0021] According to a further aspect of the present invention, it can be provided that the at least one second functional layer is formed in the form of a film, and / or that the at least one second functional layer overlaps at least section by section in a circumferential direction.

[0022] This ensures, in particular, sufficient circumferential electrical insulation of the contact element section.

[0023] It is possible that the insulating element extends along the longitudinal direction at least to a first end face and / or at least to a second end face, wherein preferably the first end face and the second end face define the heat sink along the longitudinal direction.

[0024] According to a further aspect of the present invention, it can be provided that a first sealing element and / or a second sealing element is arranged on the functional surface within the cooling channel and forms a substantially gas-tight and / or a substantially liquid-tight connection with the functional surface.

[0025] The first sealing element and / or the second sealing element can each be made of an elastomeric material. The essentially gas-tight and / or essentially liquid-tight connection ensures sufficient sealing of the cooling channel against the contact element.

[0026] It is possible that the first sealing element is arranged longitudinally on a first end wall of the cooling body and / or the second sealing element is arranged on a second end wall of the cooling body, in order to seal and / or limit the cooling channel along the longitudinal direction.

[0027] According to a further aspect of the present invention, it can be provided that the cooling element comprises an inlet for receiving the medium and an outlet for discharging the medium, wherein the inlet and the outlet are arranged and / or formed on a common side, and / or that the inlet and the outlet are arranged and / or formed adjacent to each other.

[0028] This allows a flow path of the cooling medium to be defined in conjunction with the cooling channel, which ensures effective removal of generated heat from the contact element.

[0029] According to a further aspect of the present invention, it can be provided that the cooling channel in a cross-sectional view along the longitudinal direction is characterized by a substantially annular cross-section; and / or that the cooling element extends section by section in a cylindrical shape along the longitudinal direction.

[0030] This allows for a comparatively compact design of the contact element and the heat sink. In a cross-sectional view, the contact element can be characterized by a substantially circular outer contour.

[0031] According to a second general point of view, the present invention relates to a charging connector for transmitting electrical energy and / or electrical signals, preferably to a charging station for charging electrically powered vehicles, wherein the charging connector comprises at least one contact element configured as disclosed herein.

[0032] The charging connector is preferably a handheld and / or handheld charging connector.

[0033] The embodiments and features of the present invention described above can be combined arbitrarily or expediently. Further details and advantageous effects of the present invention are explained in more detail below with reference to the accompanying figures.

[0034] They show: Fig. 1 a first embodiment of the charging connector according to the present invention in a perspective view; Fig. 2 a first embodiment of the contact element according to the present invention in a perspective view; Fig. 3 the contact element from Fig. 2 in a perspective sectional view; Fig. 4 the contact element from Fig. 2 in a sectional view; Fig. 5 the contact element from Fig. 2 in a sectional view, where a flow path of the cooling medium is shown schematically; Fig. 6 a section of the sectional view from Fig. 4 (section Y) in an enlarged view.

[0035] Identical or functionally equivalent components or elements are identified in the figures with the same reference numerals. To avoid repetition, reference is sometimes made to the descriptions of other embodiments and / or figures for their explanation.

[0036] The following detailed description of the embodiments shown in the figures serves to illustrate or clarify the invention in no way limiting its scope.

[0037] Fig. Figure 1 shows a first embodiment of a charging connector 1 according to the present invention in a perspective view.

[0038] The charging connector 1 is used to transmit electrical energy and / or electrical signals. The charging connector 1 is a mobile, handheld, hand-operated, and / or hand-carryable charging connector 1. The charging connector 1 is usually abbreviated as "charging plug".

[0039] The charging connector 1 is preferably specified according to IEC 62196-2 or IEC 62196-3, or preferably based at least partially on the requirements of IEC 62196-2 or IEC 62196-3. In other words, the charging connector 1 can be designed and / or specified according to the Combined Charging System (CCS) connector system standard as a so-called Combo 2 charging connector ("Type 2 charging connector"). In an alternative embodiment, the charging connector 1 can also be designed as a so-called Combo 1 charging connector ("Type 1 charging connector") according to US standards and / or specifications. Alternatively, the charging connector 1 may be designed and / or specified according to another standard or specification, for example, the so-called "CHAdeMO standard" or the so-called "ChaoJi stacked specification".

[0040] The charging connector 1 is configured for charging the batteries of electrically powered vehicles (electric vehicles) and, in its assembled state, is connected via a charging cable to a charging station, preferably including a charging management unit of the charging station. The charging management unit serves, among other things, to adjust, preferably control and / or regulate, the electrical energy to be transmitted via the charging cable to the charging connector 1 and subsequently to a mating connector of an electrically powered vehicle. The mating connector is generally referred to as a "charging socket".

[0041] The charging connector 1 is preferably used for charging with direct current and comprises two contact elements 100 according to the invention. An electrical voltage applied to the contact elements 100 during a charging process can, for example, be in the range of 400 volts to 800 volts. In other words, the contact elements 100 are so-called load contact elements 100 for transmitting electrical energy to the electrically powered vehicle during a charging process. The charging connector 1 is preferably configured for high-power fast charging. The electrical energy in the form of a charging voltage and / or a charging current is transmitted during a charging process from the charging station via respective electrical conductors of the charging cable, which are electrically connected to the contact elements 100.

[0042] The charging connector 1 includes further contact elements, which are located in Fig. For clarity, the contact elements shown are not labeled. The other contact elements serve to transmit electrical signals, preferably communication signals, between the charging station, the charging connector 1, and the electrically powered vehicle during a charging process. One contact element is the so-called pilot contact ("Control Pilot / CP," "CP contact element"), and another contact element is the so-called proximity contact ("Proximity Pilot / PP," "PP contact element"). In other words, the other contact elements serve for communication between the charging station, the charging connector 1, and the electrically powered vehicle, preferably during the charging process. This ensures, for example, that the transmitted electrical energy and thus the charging current is limited to prevent overloading the electrical conductors, preferably thermal overload.

[0043] Furthermore, another contact element is provided as a protective contact element (“PE contact element”) for diverting a fault current, for realizing an earth connection (equalizing a potential), for protection against electric shocks, and / or for reducing electromagnetic interference.

[0044] Fig. Figure 2 shows a first embodiment of the contact element 100 according to the present invention in a perspective view. The contact element 100 can be a component of a charging connector 1 for charging electrically powered vehicles (electric vehicles) using a charging station. It is possible that the contact element 100 is alternatively configured for further and / or other purposes and applications.

[0045] The contact element 100 is configured as a so-called load contact element 100 for the transmission of electrical energy. The contact element 100 extends essentially in and / or along a longitudinal direction L. The longitudinal direction L of the contact element 100 can be a direction in and / or along which the contact element 100 extends at its longest (maximum) length.

[0046] The contact element 100 is based on an electrically conductive material. This electrically conductive material can be, for example, copper, aluminum, and / or a copper or aluminum alloy. The contact element 1 is preferably manufactured and / or formed integrally as a single piece.

[0047] The contact element 100 comprises a plug-in section 101 for forming a plug connection with a mating contact element, in order to realize both a mechanical and an electrical connection. The plug-in section 101 is sleeve-shaped and includes several slots extending along the longitudinal direction L. The slots are not marked for clarity. In the exemplary embodiment, the contact element 100 is Fig. 2 designed as a so-called socket contact element 100 (abbreviated "socket contact").

[0048] The contact element 100 includes a mounting section 103 for fastening and / or supporting the contact element 100. The mounting section 103 can, for example, include an internal thread for fastening and / or supporting the contact element 100.

[0049] According to the invention, the contact element 100 comprises a heat sink 200. The heat sink 200 is integrally manufactured as a single piece. Alternatively, the heat sink 200 is possible to be made of multiple parts and, for example, to comprise at least two heat sink segments. The heat sink 200 is made of an insulating material with inherent electrical insulating properties and resulting insulating capabilities. The insulating material can be based on a plastic material. The heat sink 200 can be manufactured, for example, by at least one of the following processes: injection molding, casting, sintering, 3D printing, milling, cutting, parting, curing, or shrinking.

[0050] The heat sink 200 is configured to receive and discharge a cooling medium M. The cooling medium M is preferably a flowable and / or liquid cooling medium M, configured to absorb generated heat. The heat sink 200 extends to form a cooling channel 203 (see [reference]). Fig. 3) essentially along the longitudinal direction L of the contact element 100 and encloses the contact element section 102. The cooling channel 203 forms a cavity for the cooling medium M. The contact element section 102 represents a transition section 102, which is arranged between the plug-in section 101 and the assembly section 103. Unlike the plug-in section 101, the contact element section 102 is made of solid material and is therefore solid.

[0051] The heat sink 200 extends along the longitudinal direction L in a sectioned cylindrical shape. On one outer side, the heat sink 200 is defined by the outer surface 202. The outer surface 202 transitions along the longitudinal direction L into the respective end faces 204 and 205 of the heat sink 200, of which in Fig. 2 the end face 204 is visible and marked, and the end face 205 is indicated by a dashed line. The end face 204 is formed by the end wall 241 of the heat sink 200, and the end face 205 is formed by the end wall 242 of the heat sink 200, which in Fig. The two openings are each indicated by a dashed line. The heat sink 200 can be attached and / or slid onto the contact element 100 through respective through-openings in the end walls 241 and 242 along the longitudinal direction L. For clarity, the through-openings are not marked. The through-openings in the end walls 241 and 242 are each characterized by a cross-section that is essentially complementary to the cross-section of the contact element 100.

[0052] The outer surface 202 extends along a circumferential direction U around the contact element 100, that is, around the contact element section 102, in order to enclose the contact element section 102.

[0053] The cooling element 200 comprises the inlet 211 for receiving the cooling medium M into the cooling channel 203. The cooling element 200 comprises the outlet 212 for discharging the cooling medium M, preferably the heated cooling medium M for the removal of generated heat. It is understood that both the inlet 211 and the outlet 212 can be connected to respective lines for guiding the cooling medium M to and from the cooling element 200, for example by forming a screw connection.

[0054] The inlet 211 and the outlet 212 are arranged and / or formed on a common side S. Furthermore, the inlet 211 and the outlet 212 are arranged and / or formed adjacent to each other. This allows, for example, the effectiveness of the cooling medium M within the cooling channel 203 to be further increased. The cooling channel 203 serves to flush the contact element section 102 with the cooling medium M, which is illustrated in more detail with reference to the following figures.

[0055] Fig. Figure 3 shows the contact element 100. Fig. 2 for further illustration in a perspective sectional view.

[0056] The contact element 100 comprises an insulating element 220 for insulating the contact element section 102. The insulating element 220 extends along the longitudinal direction L at least to the first end face 204 and at least to the second end face 205, such that in a radial direction the end walls 241 and 242 are arranged opposite each other at their respective through-openings for the contact element 100 to the insulating element 220.

[0057] To seal the cooling channel 203, two sealing elements 231 and 232 are arranged on the insulating element 220 within the support body 200 and thus within the cooling channel 203. The sealing elements 231 and 232 are preferably designed as so-called O-rings for sealing the cooling channel 203. The sealing element 231 is arranged on the end wall 241 and the sealing element 232 on the end wall 242.

[0058] The arrangement of a sealing element 231, 232 on the insulating element 220 and the configuration of the insulating element are described in more detail below.

[0059] Fig. Figure 4 shows the contact element 100. Fig. 2 additionally in a sectional view and Fig. Figure 5 shows the contact element 100. Fig. 2 also in a sectional view, in which a flow path of the cooling medium M is shown schematically, which results from the jacket-shaped or hollow cylindrical configuration of the cooling body 200 as well as the arrangement of the inlet 211 and the outlet 212.

[0060] From the sectional views in the Fig. 4 and Fig. Figure 5 shows that the cooling channel 203 is essentially characterized by an annular cross-section in a sectional view along the longitudinal direction L.

[0061] Fig. Figure 6 shows a section of the sectional view from Fig. Figure 4 (section Y) shows an enlarged view illustrating the configuration of the insulating element 220, which serves to insulate the contact element section 102. The contact element 100 is thus characterized by an indirect cooling system in which there is no contact between the cooling medium M and the contact element 100.

[0062] The insulating element 220 comprises a first functional layer 221. The first functional layer 221 includes a functional surface 222.1 for accommodating a sealing element 231, 232 for sealing the cooling channel 203. The functional surface 221.1 is characterized by a defined roughness and / or is preferably designed as a substantially smooth functional surface 221.1. The defined roughness of the functional surface 221.1 can, for example, be in a range between approximately Ra 0.2 µm and approximately Ra 0.8 µm. A substantially gas-tight and / or a substantially liquid-tight connection V is formed between the functional surface 221.1 and the sealing element 231, 232, which is Fig. 6 is graphically illustrated with an indicated sealing element 232.

[0063] The functional layer 221 is essentially tubular and encases at least the contact element section 102 along the longitudinal direction L in the circumferential direction U. The functional layer 221 is preferably in the form of a film. The functional layer 221 is preferably made of a shrinkable material and / or arranged on the contact element section 102 by a shrinking process, preferably according to the principle of a heat-shrink tube.

[0064] The insulating element 220 comprises a second functional layer 222, which is arranged between the first functional layer 221 and the contact element 100, i.e., the contact element section 102. In other words, the functional layer 222 is an inner functional layer of the insulating element 220, whereas the functional layer 221 is an outer functional layer of the insulating element. The functional layer 222 can preferably be in the form of a film. The functional layer 222 is configured for the electrical insulation of the contact element section 102 and is therefore made of a suitable material. The material of the functional layer 222 can be a plastic material, preferably from the polyimide group. In other words, the second functional layer 222 can be a polyimide film, which is characterized, for example, by a comparatively high dielectric strength.The functional layer 222 is configured to form a substantially material-bonded connection. The functional layer 222 can be an adhesive functional layer 222. The functional layer 222 is preferably bonded to the contact element section 102 and forms an adhesive bond with the contact element section.

[0065] As can be seen from the presentation in Fig. As a result of 6, the functional layer 222 overlaps at least section by section in the circumferential direction U. This allows sufficient electrical insulation to be achieved in the circumferential direction U and along the extent of the contact element section 102 in the longitudinal direction L.

[0066] The contact element 100 according to the present invention is characterized by an improved cooling concept.

[0067] The present invention is not limited to the embodiments described above. Rather, a multitude of variants and modifications are possible, which also make use of the inventive concept and therefore fall within the scope of protection. Preferably, the present invention also claims protection for the subject matter and features of the dependent claims independently of the referenced claims. Reference symbol list 100 contact elements 101 Plug section 102 Transition section 103 Assembly section 200 heat sinks 201 length 202 outdoor area 203 Cooling channel 204 Front surface 205 Front surface 211 Admission 212 Outlet 220 Insulation element 221 Functional layer 221.1 Functional interface 222 Functional layer 231 Sealing element 232 Sealing element 241 Front wall 242 Front wall L Longitudinal direction M Cooling medium S page V connection W heat QUOTES INCLUDED IN THE DESCRIPTION

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

[0000] DE 10 2022 103 224 A1

[0005] DE 10 2020 107 296 A1

[0005] EP 3 103 173 B1

[0005] Cited non-patent literature

[0000] Standard IEC 62196-2

[0039] Standard IEC 62196-3

[0039] IEC 62196-3

[0039]

Claims

A contact element (100) for transmitting electrical energy, preferably for a charging connector (1), comprising: a heat sink (200) for receiving and discharging a cooling medium (M), which, to form a cooling channel (203) along a longitudinal direction (L) of the contact element (100), encloses a contact element section (102) of the contact element (100) in order to flush the contact element section (102) with the cooling medium (M) within the cooling channel (203); wherein, for insulating the contact element section (102), an insulating element (220) with at least one first functional layer (221) is arranged on the contact element section (102), wherein the at least one first functional layer (221) for arranging at least one sealing element (231, 232) for sealing the cooling channel (203) comprises a functional surface (221.1) which is characterized by a defined roughness, wherein the functional surface preferably (221.1) is a smooth functional surface (221.1). Contact element (100) according to claim 1, wherein the at least one first functional layer (221) is formed in the form of a film and / or tube and encloses the contact element section (102) in a circumferential direction (U). Contact element (100) according to claim 1 or 2, wherein the at least one first functional layer (221) is formed from a shrinkable material and / or is arranged on the contact element section (102) by a shrinking process, preferably according to the principle of a shrink tube. Contact element (100) according to one of the preceding claims, wherein the insulating element (220) comprises at least a second functional layer (222) which is configured for electrical insulation of the contact element section (102) and / or which is configured to form a material-bonded connection, preferably an adhesive connection, with the contact element section (102). Contact element (100) according to claim 4, wherein the at least one first functional layer (221) and the at least one second functional layer (222) enclose the contact element section (102) in a circumferential direction (U) forming a prestress. Contact element (100) according to one of the preceding claims, wherein the at least one second functional layer (222) is formed in the form of a film, and / or wherein the at least one second functional layer (222) overlaps at least section by section in a circumferential direction (U). Contact element (100) according to one of the preceding claims, wherein the insulating element (220) extends along the longitudinal direction (L) at least to a first end face (204) and / or at least to a second end face (205), wherein preferably the first end face (204) and the second end face (205) define the heat sink (200) along the longitudinal direction (L). Contact element (100) according to one of the preceding claims, wherein a first sealing element (231) and / or a second sealing element (232) is arranged on the functional surface (221.1) within the cooling channel (203) and each forms a gas-tight and / or liquid-tight connection (V) with the functional surface (221.1). Contact element (100) according to claim 8, wherein the first sealing element (231) is arranged in the longitudinal direction (L) on a first end wall (241) of the cooling body (200) and / or the second sealing element (232) is arranged on a second end wall (242) of the cooling body (200) in order to seal and / or limit the cooling channel (203) along the longitudinal direction (L). Contact element (100) according to one of the preceding claims, wherein the heat sink (200) comprises an inlet (211) for receiving the medium (M) and an outlet (212) for discharging the medium (M), wherein the inlet (211) and the outlet (212) are arranged and / or formed on a common side (S), and / or wherein the inlet (211) and the outlet (212) are arranged and / or formed adjacent to each other. Contact element (100) according to one of the preceding claims, wherein the cooling channel (203) is characterized in a cross-sectional view along the longitudinal direction (L) by an annular cross-section; and / or wherein the cooling element (200) extends section by section in a cylindrical shape along the longitudinal direction (L). Charging connector (1) for transmitting electrical energy and / or electrical signals, preferably to a charging station for charging electrically powered vehicles, wherein the charging connector (1) comprises at least one contact element (100) configured according to one of the preceding claims.

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