Connectors and connector systems for automotive applications

Abstract

The invention relates to a connector (10) for automotive applications, in particular a connector (10) for an electric or hybrid vehicle, comprising a housing (11), at least two plug contacts (12, 13) arranged in the housing (11) and at least one electromagnetic connection unit (14) for generating a magnetic holding force (F), whereby the connector (10) can be coupled to a corresponding connector (20) with corresponding plug contacts (22, 23), wherein the magnetic holding force (F) is controllable.

Description

[0001] The invention relates to a connector with the features of independent claim 1, a connector system with the features of independent claim 7, and a motor vehicle with the features of independent claim 10.

[0002] Connectors and connector systems are used in numerous locations throughout vehicles to connect electrical or electronic components, control units, and other vehicle parts, enabling the transmission of electrical energy and / or signals. Hybrid and electric vehicles present additional challenges. In the event of a crash, the high-voltage battery powering the vehicle's electric drive should ideally not become an additional hazard. One danger is that parts of the vehicle, particularly the body, can become energized, potentially endangering first responders and / or firefighters. Accordingly, solutions already exist on the market to de-energize the battery in a crash and minimize this risk. However, this usually results in battery destruction and carries the risk of fire or overheating.

[0003] The high-voltage battery is typically connected to the vehicle's high-voltage electrical system via a mechanical plug connection. Disconnecting this connection therefore requires manual operation by a person. Consequently, it is not possible to disconnect the high-voltage battery and electrical system without damaging the connection. In the event of a crash, this could mean that the cable of one connector (on the high-voltage system side) becomes the weak point of the connection and could tear under mechanical stress on the battery or electrical system. The contacts could then be exposed and, due to the remaining connection to the battery, pose a hazard because electrical current could be conducted through them.

[0004] Solutions for plug connections, particularly for high-voltage batteries, are known from the prior art. For example, DE 10 2016 205 171 A1 discloses a detachable connector for automotive applications, comprising a housing with plug contacts arranged within it, and an electromagnetic unit. This unit serves to detect a proper connection between the connector and a corresponding connector. Accordingly, the electromagnetic connection unit is configured to transmit or indicate the plug-in status, or to emit a signal that reflects the plug-in status. Furthermore, the connector has plug contacts that can be connected to corresponding plug contacts by means of a detachable press fit.

[0005] DE 103 33 403 A1 relates to a connector system with a socket, a plug that can be inserted into the socket and connected to a connecting cable, and retaining means for releasably holding the plug in the socket. According to the invention, the retaining means have at least one magnet arranged in the plug and / or the socket. Applications include, for example, connectors in the healthcare sector.

[0006] DE 20 2015 002 228 U1 discloses a lockable mating-socket system. The socket or plug for connecting to a mating part comprises: a conductor contact usable for making a connection to a mating part, comprising: a coil for generating a magnetic field, wherein the coil generates the magnetic field when voltage is applied to the coil, and the coil does not generate a magnetic field when no voltage is applied to the coil.

[0007] From DE 10 2021 201 472 A1, a contact unit for establishing an electrically conductive connection is known, comprising a first connecting part with a first electrical contact and a second connecting part with a second electrical contact, wherein the first connecting part comprises a first section and a second section; the first connecting part is positionable relative to the second connecting part along a contacting axis in a rest position; the first electrical contact and the second electrical contact are configured to establish an electrically conductive connection between the first connecting part and the second connecting part upon contact, which is configured to conduct electrical energy; the contact unit further comprises a positioning unit for a rest position;an actuator configured to displace the second section of the first connecting part in the contacting direction relative to the first section.

[0008] A disadvantage of the intended press fit is that the holding force is undefined, so it is not possible to determine whether there is sufficient holding force for the connection, or whether the connection can be loosened without damage after installation in the vehicle.

[0009] It is therefore an object of the present invention to overcome at least one of the disadvantages of connectors described above, at least partially. In particular, it is an object of the invention to provide a connector that can further improve safety, especially in electric and hybrid vehicles.

[0010] The foregoing problem is solved by a connector having the features of independent claim 1, by a connector system having the features of independent claim 7 and by a motor vehicle having the features of independent claim 10.

[0011] Further features and details of the invention will become apparent from the dependent claims, the description, and the drawings. Features and details described in connection with the connector according to the invention naturally also apply in connection with the connector system according to the invention and / or in connection with the motor vehicle according to the invention, and vice versa, so that the disclosure regarding the individual aspects of the invention always refers, or can refer, to each other.

[0012] The invention provides a connector for automotive applications, in particular connectors for electric or hybrid vehicles, comprising a housing, at least two plug contacts arranged in the housing, and at least one electromagnetic connection unit for generating a magnetic holding force, thereby enabling the connector to be coupled to a corresponding connector with corresponding plug contacts. The magnetic holding force is controllable and / or adjustable. This can be understood to mean that the electromagnetic connection unit is designed such that, in addition to a purely mechanical holding force, e.g., due to the plug contacts or corresponding plug contacts, a holding force is provided that is adjustable. Besides the essentially undefined mechanical force resulting from the mechanical connection of the plug contacts, the invention makes it possible to provide a definable holding force.Controllable and / or adjustable means that at least two, preferably at least three, states or differing holding forces are possible. Firstly, a (magnetic) holding force can be provided that enables a reliable and secure connection. Furthermore, according to the invention, the holding force can be reduced to a level that allows the connection to be released with a corresponding connector with minimal or no resistance. This can be the case, for example, when the electromagnetic connection unit is de-energized, so that no or only very weak magnetic forces are present. In addition, it is conceivable that at least one further (at least a third) state is provided, which, for example, simplifies assembly or maintenance.

[0013] Preferably, the connector is a connector for connecting a high-voltage battery to the mains. In particular, the connector according to the invention ensures that movement of the high-voltage battery, especially in the event of a crash, does not subject the connector to high mechanical forces that could lead to the destruction of a high-voltage cable.

[0014] Within the scope of the invention, it can be advantageous for the electromagnetic connection unit to have an inductor connected to a control current line for supplying the inductor with a control current, so that the magnetic effect of the inductor can be controlled and / or regulated by modulating the control current. This makes it possible to provide the at least two intended states or different holding forces. The control current line is connected to a control unit, in particular a digital control unit. The control unit can be a vehicle control unit or a battery control unit. Additionally, a ground line for the electromagnetic connection unit can be provided. The control unit is designed such that the control current for the electromagnetic connection unit, in particular the inductor, is controllable and / or regulated.It is advantageous if the control current can be controlled and / or regulated, and thus adjusted, by means of modulation or a modulation method. The magnetic effect of the inductor, and therefore the holding force of the connector, is determined by modulating the control current. It is therefore possible to adjust the holding force by means of modulation in such a way that at least two different holding forces are available.

[0015] Within the scope of the invention, it is conceivable that the inductor comprises at least one coil, preferably with an iron core arranged within the coil. Providing a coil enables a cost-effective design. Furthermore, it simplifies the manufacturing of the connector. The coil can, for example, be arranged within the housing, particularly by being potted. This makes the coil insensitive to external environmental influences, thus further increasing reliability. The at least one coil is preferably arranged longitudinally along the connector's contacts. This means the coil preferably has the same orientation as the contacts, ensuring particularly reliable transmission of the magnetic holding force.

[0016] It may be provided within the scope of the invention that the control current is modulatable depending on a crash signal. Nowadays, vehicles sometimes have a sensor-based system that serves to determine collision information describing a possible impending collision. Such a system is often also referred to as a "pre-crash system." Corresponding environmental sensors, for example radar sensors, which are installed in the area of ​​the front and rear bumpers and which may also serve or be assigned to other driver assistance systems or similar, are used to acquire relevant environmental information, in particular information concerning other vehicles in the vicinity. This information, which includes distance information, speed information, and possibly trajectory information, etc., is used to determine the appropriate course of action.The system, or pre-crash system, is capable of estimating whether and, if so, when a potential collision will occur. An environmental sensor is a sensor system / sensor that incorporates environmental information, such as data from radar and / or lidar systems, as well as vehicle dynamics information, to achieve optimal occupant protection in the event of a collision. Depending on the function, "optimal" means enabling a very fast reaction time for triggering / activating safety systems. In this context, the term "environmental sensor" also includes one or more sensors that detect physical effects in the surrounding environment or on the vehicle itself. This includes video and / or ultrasonic sensors.

[0017] The connector according to the invention, in conjunction with a crash signal from a previously described pre-crash system, can now control and / or regulate the electromagnetic holding force. For this purpose, the control current is modulated as previously explained, allowing at least two different electromagnetic holding force strengths to be set. The crash signal thus ensures, in particular, that the magnetic holding force is reduced to a minimum, so that the connector can be detached from the corresponding connector with minimal or no resistance. This further increases safety. Specifically, it is possible to disconnect the connector early in a crash, so that the high-voltage network on the drive side of the vehicle is de-energized as soon as the connection is disconnected.

[0018] It is also conceivable that the electrical connection unit includes at least one magnet. In particular, the magnet can be a permanent magnet. The magnet, especially the permanent magnet, serves to provide a basic holding force for the connector. Particularly in cases where no or insufficient electrical energy is available to power the electromagnetic connection unit, especially the inductor, the magnet can provide sufficient holding force for assembly. This can be particularly advantageous during initial assembly, when the vehicle is parked, or during maintenance. The basic holding force generated by the magnet can therefore be helpful and advantageous for assembly, for example, when connecting the connector to a corresponding connector.

[0019] Permanent magnets are particularly reliable in this application. They are advantageous because no external power supply is required to generate a magnetic field, making them energy-efficient and cost-effective. Furthermore, a permanent magnet enables a compact and lightweight connector design. Permanent magnets also require little maintenance and have a long service life. The magnet, especially a permanent magnet, is preferably located within the connector housing, specifically embedded in and / or overmolded into the housing. The magnet can, for example, be designed as a ring magnet and arranged around the plug contacts. Multiple magnets can also be provided, positioned at different locations within or on the housing. It is generally advantageous if at least one magnet is located in the area or on the end face of the connector where the plug contacts extend away from the housing.

[0020] It is also conceivable that the plug contacts are each designed as plug contact pins. For the purposes of this invention, a plug contact pin is understood to be a male plug contact. In particular, if the connector is such a connector for an electric or hybrid vehicle and is located on the high-voltage side of the drive system, this ensures that the freely movable connector is de-energized after disconnection. Consequently, there is no risk of electrical energy being unintentionally transferred to other vehicle components. The male plug contacts, especially exposed or open plug contacts, are thus located on the vehicle side; that is, there is no applied voltage because the connection to the high-voltage battery is, or can be, disconnected in the event of a crash.

[0021] The above-mentioned problem is further solved by a connector system according to the invention for automotive applications, in particular for an electric or hybrid vehicle, comprising a connector according to one of the preceding claims and a corresponding connector with corresponding plug contacts. The connector system is thus intended to be, in particular, a plug connection between a high-voltage network on the vehicle side and a high-voltage battery. This plug connection has previously been designed as a purely mechanical connection. Up to now, these plug connections have generally been designed in such a way that disconnection during driving or in the event of a crash is impossible. However, the connector system according to the invention makes it possible to provide a plug connection in which controlled disconnection of the plug connection can be achieved.For this purpose, an electromagnetic connection unit is provided, which supplies a magnetic holding force that is controllable and / or adjustable. If the system is used in an electric or hybrid vehicle, the high-voltage battery can be selectively disconnected from the high-voltage network, in particular without causing damage.

[0022] This results in the same advantages with regard to a connector system according to the invention as have already been described with regard to a connector according to the invention.

[0023] The connector system according to the invention, in particular the magnetic holding force, can advantageously be adjusted by means of a control unit, preferably a digital control unit. The holding force can thus be defined according to the application. In the event of a crash, the magnetic holding force can be reduced to a minimum, so that the connection between the connector and its corresponding connector can be easily disconnected. It is conceivable that the connector system according to the invention could be used in a hybrid or electric vehicle. The vehicle has a high-voltage battery. The high-voltage battery is arranged and secured within the vehicle. In the event of a crash, the forces involved or intentional mechanisms may cause the high-voltage battery to leave its intended position in the vehicle. There are solutions in which the battery can / should also be removed from the vehicle.This movement of the battery means that the connector between the high-voltage network and the high-voltage battery is subjected to significant mechanical forces. To ensure reliable disconnection of the connection, the proposed connector system allows for the control and / or regulation of the holding force of both connector components (connector and corresponding connector).

[0024] In particular, at least two different holding forces can be provided. Firstly, a magnetic holding force can be generated that securely holds a connection, preventing it from coming loose during normal driving. Secondly, the magnetic holding force can be reduced to such an extent that the connectors can be detached or removed in the event of a crash or pre-crash.

[0025] It is also conceivable that the corresponding connector has at least one magnet. The magnet interacts with the electromagnetic connection unit, in particular the inductor of the connector's electromagnetic connection unit. Thus, a reliable connection between the connector and its corresponding connector is proposed, in which the magnetic holding force is adjustable and / or controllable. The magnet is advantageously arranged analogously to the electromagnetic connection unit, in particular the inductor, of the connector. This means that the interacting components of the electromagnetic connection unit, in particular the connector's inductor and the magnet, are arranged at opposite locations in or on the respective housing, so that a reliable magnetic holding force can be generated.

[0026] The magnet is particularly advantageous as a permanent magnet. Permanent magnets are beneficial because no external power supply is required to generate a magnetic field, making them energy-efficient and cost-effective. Furthermore, a permanent magnet allows for a compact and lightweight connector design. A permanent magnet also requires little maintenance and has a long service life.

[0027] The connector system according to the invention, consisting of a connector and corresponding connector and a proposed electromagnetic connection unit, also makes it possible to determine, transmit, or indicate the mating status, or to output a corresponding signal that reflects the status. Accordingly, safety can be further increased. Furthermore, additional sensors for detecting the connection can be dispensed with.

[0028] The above problem is further solved by a motor vehicle according to the invention, in particular an electric or hybrid vehicle, with a connector system according to one of claims 7 to 9.

[0029] This results in the same advantages with regard to a motor vehicle according to the invention as have already been described with regard to a connector according to the invention and / or a connector system according to the invention.

[0030] Further advantages, features, and details of the invention will become apparent from the following description, in which an embodiment of the invention is described in detail with reference to the drawings. The features mentioned in the claims and in the description can each be essential to the invention individually or in any combination. The drawings schematically illustrate: Fig. 1 a possible embodiment of the connector system according to the invention with a connector according to the invention and Fig. 2 a motor vehicle with a connector system according to the invention.

[0031] The figures use identical reference numerals for the same technical features, even for different embodiments.

[0032] In the Fig. Figure 1 shows a connector system 100 for use in an electric or hybrid vehicle. A high-voltage battery 210 is provided, which has a corresponding connector 20. The corresponding connector 20 is thus located on the battery side and therefore on the current-carrying side. The corresponding connector 20 comprises two plug contacts 22, 23, which, in the illustrated embodiment and preferably, are designed as sockets (female plugs). The plug contacts 22, 23 are arranged in the housing 21 of the corresponding connector 20. The housing 21 is preferably designed as an injection-molded plastic part. This enables cost-effective manufacturing. Furthermore, the corresponding connector 20 is equipped with a magnet 24. This magnet 24 can preferably be a permanent magnet.In the illustrated embodiment, the magnet 24 is arranged in the housing 21, in particular by overmolding. However, it is conceivable that the magnet 24 is also arranged on an outer surface of the housing 21. It is also conceivable that the magnet 24 is designed as a ring magnet and / or that several magnets 24 are provided at different positions on or in the housing 21.

[0033] Furthermore, the Fig. 1. A connector 10 according to the invention of a connector system 100 according to the invention. The connector 10 comprises a housing 11 and at least two plug contacts 12, 13 arranged in the housing 11. In the illustrated embodiment, the plug contacts 12, 13 are each designed as plug contact pins (male plug contacts). These plug contacts 12, 13 serve for the electrical connection with the battery 210. For this purpose, the plug contacts 12, 13 are contacted with the plug contacts 22, 23 of the corresponding connector 20. In the illustrated example, the male plug contacts 12, 13 of the connector 10 are inserted into the female plug contacts 22, 23, thus establishing an electrical connection.

[0034] The connector 10 further comprises an electromagnetic connection unit 14 by means of which a magnetic holding force F can be generated, thereby enabling the connector 10 to be coupled with the corresponding connector 20. The electromagnetic connection unit 14 interacts with the magnet 24 of the corresponding connector 20. For this purpose, the electromagnetic connection unit 14 includes an inductor 15. In the illustrated embodiment, the inductor 15 preferably comprises at least one coil 15.1 and an iron core 15.2 arranged in the coil 15.1. The inductor 15 is arranged longitudinally in the housing 11 along the plug contacts 12, 13. Furthermore, the inductor 15 is arranged in the housing 11 of the connector 10 such that interaction with the magnet 24 of the corresponding connector 20 is enabled.This ensures that a sufficiently large holding force F can be reliably provided. The holding force F ensures that both connectors 10 and 20 are reliably engaged with each other. In the event of a crash, the holding force F can be reduced accordingly by means of the electromagnetic connection unit 14, so that the two connectors 10 and 20 can be separated with minimal resistance.

[0035] Furthermore, connector 10 in the Fig. 1. Two magnets 17 are mounted. The magnets 17 are spaced apart from each other in the housing 11, in particular encapsulated. The magnets 17 make it possible, in particular, to provide a basic holding force. This is especially advantageous when no power supply is available (e.g., during initial assembly or maintenance). It is also conceivable to provide only one magnet 17, which provides a basic holding force. In this case, the magnet 17 can also be designed as a ring magnet. Preferably, the ring magnet then extends in a ring shape around the plug contacts 12, 13. A magnetic component is then provided on the corresponding connector 20, or the housing 21 is magnetically formed in the corresponding area of ​​the magnet 17, so that the magnet 17 can transmit a magnetic force to the corresponding connector 20.

[0036] Furthermore, in the Fig. Figure 1 shows that connector 10 has a control current line 16 and a ground line 18. The control current line 16 and / or the ground line 18 are connected to a control unit. The control unit can be, in particular, the vehicle control unit. The control current line 16 and the ground line 18 are connected at their other end to the electromagnetic connection unit 14. The holding force F can be controlled and / or regulated by means of the control current line 16. The control unit is preferably equipped with or connected to a pre-crash or crash system. Nowadays, vehicles sometimes have such a sensor-based system, which serves to determine collision information describing a possible impending collision. These systems can create or generate a crash signal, so that the holding force F is controlled and / or regulated depending on this signal.

[0037] If a pre-crash or crash system detects an accident (crash), the control unit can modulate the control current and thus control the electromagnetic connection unit 14 and the holding force F it generates. If the crash system detects an accident, the holding force F can be reduced so that the connection between connector 10 and the corresponding connector 20 can be disconnected with minimal force or resistance. Disconnecting the connector relieves strain on connector 10 of the vehicle 200. This minimizes the risk of mechanical damage to connector 10 and / or the corresponding connector 20 and / or the transmission of electrical current to the vehicle 200 or the body through the end of connector 10.

[0038] The Fig.Figure 2 shows a vehicle 200 in the form of an electric or hybrid vehicle. The vehicle 200 has a high-voltage battery 210. The high-voltage battery 210 is connected to the high-voltage network of the vehicle 200 (on the drive side) by means of a connector system 100 according to the invention. The connector system 100 has a connector 10 on the high-voltage network side of the vehicle 200 and a corresponding connector 20 on the high-voltage battery side.

[0039] The high-voltage battery 210 can be detachably mounted in the vehicle 200. If an accident (crash) occurs, the crash system or pre-crash system detects this and can reduce the holding force F. If the high-voltage battery 210 is moved by the accident or even ejected from the vehicle 200, the connector system 100 according to the invention allows the connector 10 on the high-voltage network side of the vehicle 200 to be disconnected from the corresponding connector 20 on the battery side without damage. This reduces the mechanical stress on the connector 10 and / or the corresponding connector 20. The battery's trajectory is thus not affected by a disruptive force. Reference symbol list 10 connectors 11 cases 12, 13 plug contacts 14 Connection unit 15 Inductance 15.1 Coil 15.2 Iron core 16 Control current line 17 Magnet 18 Ground wire 20 connectors 21 cases 22, 23 plug contacts 24 Magnet 100 connector system 200 vehicles 210 high-voltage battery F Holding force

Claims

[1] Connectors (10) for automotive applications, in particular connectors (10) for an electric or hybrid vehicle, with a housing (11), at least two plug contacts (12, 13) arranged in the housing (11) and at least one electromagnetic connection unit (14) for generating a magnetic holding force (F), whereby the connector (10) can be coupled to a corresponding connector (20) with corresponding plug contacts (22, 23), and wherein the magnetic holding force (F) is controllable. [2] Connector (10) according to claim 1, characterized by , that the electromagnetic connection unit (14) has an inductance (15) which is connected to a control current line (16) to supply the inductance (15) with a control current, so that the magnetic effect of the inductance (15) can be controlled by modulating the control current. [3] Connector (10) according to claim 2, characterized by, that the inductance (15) comprises at least one coil (15.1), preferably with an iron core (15.2) arranged in the coil (15.1). [4] Connector (10) according to any one of the preceding claims, characterized by , that the control current can be modulated depending on a crash signal. [5] Connector (10) according to any one of the preceding claims, characterized by that the electrical connection unit (14) has at least one magnet (17). [6] Connector (10) according to any one of the preceding claims, characterized by , that the plug contacts (12, 13) are each designed as plug contact pins. [7] Connector system (100) for automotive applications, in particular for an electric or hybrid vehicle (200), comprising a connector (10) according to one of the preceding claims and a corresponding connector (20) with corresponding plug contacts (22, 23). [8] Connector system (100) according to the preceding claim, characterized by , that the corresponding connector (20) has at least one magnet (24). [9] Connector system (100) according to the preceding claim, characterized by , that the magnet (24) is designed as a permanent magnet. [10] Motor vehicle (200), in particular electric or hybrid vehicle, with a connector system (100) according to one of claims 7 to 9.

Images