Bimettalic connector for charging cables, for high voltage applications

Abstract

The invention relates to a connector for charging cables, comprising at least one or more connecting elements, the connecting element being bimetallic.

Description

[0001] Bimetallic charging cable connector for high-voltage applications

[0002] The subject matter relates to a charging cable connector, a method for its production, a charging socket, and a system for power transmission for high-voltage applications.

[0003] One of the greatest challenges of electrifying mobility lies in minimizing the charging times of the energy storage systems involved. The tank of a conventional vehicle with a combustion engine can be filled with fuel within a few minutes, containing enough energy for hundreds of kilometers of driving. The situation is different, however, for electric vehicles, which typically require a high-capacity electric battery to be charged at a charging station. High currents and voltages are used to charge the battery as quickly as possible, ideally significantly faster than it is subsequently discharged during ferry operation.

[0004] To transfer the necessary high charging power from the charging station to the vehicle's battery, the entire transmission path from the charging station socket via the vehicle's socket to the battery must have excellent electrical conductivity. In particular, all transitions between the individual components of the transmission path must exhibit particularly low contact resistance.

[0005] Despite low contact resistances, high Joule power losses occur, particularly at transfer points between charging stations and vehicles, i.e., especially in charging sockets and their surroundings. This is due to the high charging currents and voltages. The resulting heat must first be absorbed by the components involved without causing damage through overheating. Therefore, the components must have a high heat capacity before the heat can be dissipated. For this purpose, a low thermal resistance to the environment is desirable.

[0006] At the same time, the automotive industry is subject to strong cost pressure and a drive to keep all components as light as possible.

[0007] The object of the invention was therefore, among other things, to provide a thermally and electrically particularly well-conducting transition between a charging socket and a vehicle-side power conductor.

[0008] This object is achieved by a charging cable connector according to claim 1, a method for its production according to claim 35, a charging socket according to claim 39 and a system according to claim 41.

[0009] One aspect concerns a charging cable connector. This can be part of a charging socket and / or be formed on its own.

[0010] The connector comprises at least one connecting element made of an electrically conductive material, in particular a metal material. The connecting element can be arranged in the charging cable connector. Parts of the charging cable connector can at least partially enclose the connecting element.

[0011] A longitudinal axis can be defined for a connecting element. The longitudinal axis extends essentially along the direction of the connecting element's greatest spatial extent.

[0012] The connecting element in question comprises at least two opposing end faces. These can be substantially flat. A surface deviating from a flat shape on at least one of the end faces is also possible, for example, a rounded shape, a tapered shape, such as a conical or gable-roof-shaped taper, or another surface shape of the end faces.

[0013] An end face can represent the end of the connecting element along the longitudinal axis. Part of the connecting element can also extend beyond the end face.

[0014] Starting from a first end face of the connecting element, a first region of the connecting element extends to a central region of the connecting element. Starting from a second end face, which is opposite the first end face, a second region of the connecting element extends to the central region of the connecting element.

[0015] The central region of the connecting element can extend in the longitudinal direction of the connecting element. The central region can comprise parts of the first and / or second regions. The central region can also define a further region of the connecting element that is different from the first and second regions. The central region can be located essentially halfway along the longitudinal axis of the connecting element. The central region can also be arranged further away from one of the end faces than from the other end face.

[0016] The first region of the connecting element can have a further end face in addition to the first end face. This further end face can be oriented substantially away from the first end face. The further end face points in the direction of the second region. The further end face can be substantially flat. A surface of the further end face that deviates from a flat shape is also possible, for example a rounded shape, a pointed shape, in particular a conical, stepped and / or gable roof-shaped taper or another surface shape of the further end face. The first region of at least one of the connecting elements is in particular formed from a first material. The second region of the at least one connecting element is in particular formed from a second material.

[0017] The first and / or second material can, in particular, be an electrically conductive material. The first and / or second region of the connecting element can, in particular, be formed from a solid material. It is also possible for the first and / or second region of the connecting element to be formed from a composite material comprising several different components of different materials.

[0018] The first and / or second material can, in particular, be a metal material. The first material is therefore also referred to below as the first metal material. The second material can be referred to as the second metal material.

[0019] The first and / or second material can be, for example, copper, a copper alloy, aluminum, an aluminum alloy, or combinations thereof. Metal materials such as steel, brass, gold, or other comparable metal materials can also be used.

[0020] The second material may be different from the first material. In particular, the first material may be a first metal material, while the second material may be a second metal material different from the first.

[0021] In a preferred embodiment, the first region of the connecting element is formed from aluminum or an aluminum alloy, while the second region of the connecting element is formed from copper or a copper alloy.

[0022] For connecting elements that are typically subject to particularly high electrical and thermal stress, such as those that connect a charging socket to the vehicle's internal power supply network, solid copper elements are traditionally used. These are therefore typically made of a single material.

[0023] These must, on the one hand, be adapted to the standardized geometry of the charging boxes, and, on the other hand, exhibit sufficiently high thermal capacity and conductivity. To meet the high requirements for heat transfer and heat absorption, conventional connecting elements are often realized with a high material volume in at least one area. The provision of connecting elements is therefore associated with high material costs. This is even more true when solid copper is used, which is a relatively expensive metal compared to aluminum, for example.

[0024] The complex shape of the connecting element - on the one hand adapted to charging socket geometries, on the other hand sufficiently large volume for heat transport and heat absorption - is accompanied by complex manufacturing processes, which further increase the costs of the connecting elements in addition to the material costs.

[0025] It has been recognized that the provision of a connecting element made of two different materials, in particular two different metal materials, is advantageous.

[0026] In particular, it was recognized that not all areas of the connecting element are subject to the same level of thermal stress. It was also recognized that heat is distributed within the connecting element, so that it is sufficient for certain areas to have a high specific thermal conductivity. It was also recognized that for sufficient heat dissipation, it is sufficient if certain areas of the connecting element have a sufficiently large surface area. In particular, the parts of the connecting element which serve to absorb and dissipate heat do not have to be made of a material which is a particularly good electrical and / or thermal conductor. It was recognized that the shape of these areas has a major influence on their ability to transport, absorb and dissipate heat. The choice of shape can therefore compensate for a material which has a relatively low thermal conductivity.

[0027] Typically, the areas of a connecting element intended for thermal management are equipped with a larger volume compared to other areas of the connecting element. It has been recognized that the choice of material for these large-volume areas has a significant influence on the properties of the entire connecting element. For example, a lightweight and inexpensive material can lead to a significant reduction in the weight and cost of the entire connecting element. The areas described herein can be identified, for example, with the first area of ​​the present connecting element. The first area of ​​the present connecting element can therefore be considered, among other things, as a cooling element.

[0028] Furthermore, it was recognized that those parts of the connecting element which, due to the connector geometry of existing charging systems, have a small cross-section compared to other areas of the connecting element, are advantageously manufactured from a highly conductive material. Since these elements also come into mechanical contact with contact parts, low contact resistance is desired even at low contact pressures. By selecting a highly conductive material, excessive heating due to ohmic losses is avoided in contact regions with an already small conductor cross-section compared to the rest of the connecting element. These areas of the connecting element usually have a small volume compared to the total volume of the connecting element, in particular accounting for less than 50%.Therefore, these areas can be formed from a heavier, more expensive, highly conductive material compared to the material of other parts of the connector. The average properties of the.

[0029] The connecting element will not be unduly impaired by this. The area described here can, for example, be identified with the second area of ​​the connecting element in question. Accordingly, the second area of ​​the connecting element in question can be regarded, at least among other things, as a contact area.

[0030] For the reasons mentioned above, a design of the connecting element made of two different materials is therefore possible. Such a design results in a particularly inexpensive and lightweight connecting element. This is usually achieved by making one of the two materials particularly lightweight and inexpensive. At the same time, the thermal and electrical conductivity, as well as the ability to dissipate heat, are not significantly compromised.

[0031] Compared to a fastener design that uses only a single material, this allows for sufficiently high thermal conductivity and heat dissipation in every area of ​​the fastener. At the same time, costs and weight remain low.

[0032] Specifically, a connecting element with a second section made of copper and a first section made of aluminum can be lighter and cheaper than a connecting element made entirely of copper. If the connecting element were made solely of aluminum, disadvantages would arise which are avoided by the bimetallic design. The reduced thermal conductivity of aluminum compared to copper would lead to high electrical and thermal resistance, particularly in areas of the connecting element with a small cross-section. This would result in strong local heating during the charging process. At the same time, the areas that come into repeated contact with conductive elements during use of the connecting element would not be able to withstand the resulting mechanical stress. This is because aluminum is softer than, for example, the commonly used copper.

[0033] In a preferred embodiment, the first metal material may comprise aluminum or an aluminum alloy, while the second metal material may comprise copper or a copper alloy. The first region may thus be formed from aluminum or aluminum alloys, while the second region may be formed from copper or copper alloys.

[0034] The first area can thus serve, among other things, to absorb heat and release it into the environment. The second area can thus serve, for example, to absorb mechanical forces that occur, for example, when connecting to other elements. Due to its higher specific thermal conductivity compared to the first area, the second area can also transfer heat to the first area. Furthermore, the second area can minimize the generation of Joule power losses by ensuring low contact resistance to the elements being contacted.

[0035] In a preferred embodiment, the cross-section of the first region of at least one of the connecting elements is larger than the cross-section of the second region of the connecting element. Alternatively, the cross-sections of the two regions can also substantially coincide. The region can also have a larger cross-section than the first region.

[0036] The cross-section of a region of a connecting element is to be determined essentially perpendicular to the longitudinal extent of the connecting element. A larger cross-section is associated, among other things, with an increased material volume and thus with an increased heat capacity of the connecting element. If a first cross-section is specified as larger than a second cross-section, this can mean in the present case that the cross-sectional area of ​​the first cross-section is larger than the cross-sectional area of ​​the second cross-section. It can also mean that the first cross-section has a larger diameter in at least one direction than the second cross-section. It can also mean that the first cross-section can completely envelop the second cross-section.

[0037] In an independently inventive embodiment, the cross-section of the first region of at least one of the connecting elements can, at least in some regions, have a longer outline than the envelope of the cross-section. The length of the outline can be understood as the length of the line running along the outline.

[0038] Likewise, the cross-section can have a smaller area than the envelope of the cross-section.

[0039] The envelope of a given two-dimensional first shape can be understood in particular as the shape that completely encloses the given first shape and is simultaneously convex. The envelope is therefore convex. In a convex shape, all secants, i.e., lines between two points on the outline of the shape, lie within the shape or separate it.

[0040] In particular, the cross-section of the first region of at least one of the connecting elements can deviate from a convex shape at least in some regions. For example, a partial region of the cross-section can be concave. Exemplary at least partially concave cross-sectional shapes can be star-shaped, lamellar-shaped, serrated, corrugated, cross-shaped, kidney-shaped, or otherwise at least partially concave cross-sectional shapes. For example, the cross-section can have at least one or more elevations. The elevation can, for example, point substantially away from the center point and / or center of gravity of the cross-section. For example, the elevation can take the shape of a spike, a triangle, a curvature, a rectangle, or a combination thereof.

[0041] By providing an at least partially concave cross-section across at least part of the first region along the longitudinal axis of the connecting element, the surface area of ​​the first region in this part can be particularly large. This surface area is, in particular, part of the lateral surface of the first region. In particular, the surface area can be larger than it would be for a first region with a convex cross-section of the same cross-sectional area.

[0042] In a preferred embodiment, the first region of one of the connecting elements can have at least one cooling fin. A cooling fin can be defined in the cross-section of the first region as a raised portion protruding radially from the first region. For example, the raised portion can be defined in the cross-section as a triangle, a rectangle, or a similar shape.

[0043] In one embodiment, at least one or more or even all of the cooling fins of at least one of the connecting elements can taper towards their side facing away from the first region. This achieves high stability in the region of the transition between the first region and the cooling fin. At the same time, tapered cooling fins are characterized in their tapered end region by a particularly high surface area to volume ratio. This promotes heat dissipation from the cooling fin into the environment and thus from the connecting element to the environment. The cooling fins can also have a substantially constant width without taper. A cooling fin can be characterized in its cross-section by a large ratio between outline length and area. In particular, the ratio between a quarter of the outline length and the square root of the area of ​​the cooling fin can be greater than 1.5 or 2.In another definition, for example, the major axis of the cross section of the cooling fin may be longer than the minor axis of the cross section of the cooling fin by a factor of at least 2, 3, 4, 5, 10, or more.

[0044] In one embodiment, the length of the cooling fins can vary along the circumference of the cross-section of the first region. For example, the cooling fins on one side of the cross-section can be shorter on average and / or in total than on the side of the cross-section opposite the first side. The length of the cooling fins can be used to control heat dissipation. The side of the first region that has longer cooling fins than another side can achieve greater heat dissipation into the environment.

[0045] For example, cooling fins can also be arranged on only one side, for example, in a circular arc section of up to 45°, 60°, 75°, 90°, 135°, or 180°. One side of the cross-section of the first region can thus be free of cooling fins. This side can, for example, span an angle of at least 180°, 225°, 270°, 285°, 300°, or 315°.

[0046] The at least one cooling fin can in particular run substantially parallel to the longitudinal axis of the connecting element.

[0047] For example, the cross-section of the first region and / or of the cooling fin can remain substantially constant along the entire length of the first region along the longitudinal axis of the connecting element. This results in a simple manufacturing option for the first region in a continuous casting process, extrusion process, or similar continuous manufacturing processes in which a product (for example a semi-finished product) is manufactured with a constant cross-section along a longitudinal direction. In one embodiment, the cooling fin can, for example, extend substantially along the entire length of the first region. The cooling fin can also be interrupted along the longitudinal axis of the connecting element. The cooling fin protruding from the first region can therefore have a gap. This can further increase the surface area of ​​the cooling fin.

[0048] In one embodiment, a plurality of such cooling fins are arranged on the first region.

[0049] In a particularly preferred embodiment, cooling fins are arranged circumferentially around the first region. This can mean, in particular, that cooling fins are provided that protrude on all sides in cross-section perpendicular to the longitudinal axis of the connecting element. For example, at least 5, 10, 15, and / or more cooling fins can be arranged in the first region.

[0050] The cooling fins can be distributed substantially regularly around the circumference of the first region, i.e., with substantially equal angular sections relative to one another. The cooling fins can also be arranged at varying degrees of proximity to one another around the first region.

[0051] In a preferred embodiment, the cooling fins of at least one of the connecting elements may differ from one another in their length perpendicular to the longitudinal axis of the connecting element.

[0052] To describe the cooling fin distribution around the first region, at least two circular segments of the cross-section of the first region can be defined. The circular segments are arranged, for example, around the center point, for example the geometric center of gravity of the cross-section of the first region. For example, the first region can be halved into two semicircular circular segments. Other circular segments can also be defined, for example a first circular segment of 90° and a second of 270°, which do not overlap and each define a contiguous circular segment. More than two circular segments can also be defined. The properties of the cooling fins can now be compared between the circular segments. The properties of the cooling fins can differ between two given circular segments.

[0053] Example properties of the cooling fins in a circular segment are the length of the longest cooling fin, the area of ​​the largest cooling fin, the number of cooling fins, the average length of the cooling fins, the average cross-sectional area of ​​the cooling fins, the average outline length of the cooling fins.

[0054] For the sake of simplicity, the cross-section of the first region of the connecting element in question can now be divided into two circular segments, a first and a second, each spanning 180° and not overlapping each other. In this case, the two circular segments are therefore semicircles. For at least one such division of the cross-section of the first region of the connecting element, the cooling fins in the first circular segment can be more numerous, longer, have a higher surface area, and / or a longer outline than the cooling fins in the second circular segment.

[0055] The properties length, area, outline length can be averaged or summed over the cooling fins in the respective circular section, for example.

[0056] The demarcation between a respective cooling fin and the rest of the first region of the connecting element in cross-section can, for example, be made such that the cross-section of the first region is filled with a convex surface with maximum area. The convex surface is completely contained within the cross-section of the first region. The convex surface and the outline of the cross-section touch at two or more points. The parts of the cross-section of the first region that do not lie within this convex surface can be considered cooling fins. This definition of a cooling fin in cross-section can be applied to all aspects of the subject matter.

[0057] The cross-section of the first region can be shaped by the dimensioning of the cooling fins. Here, the envelope of the cross-section of the first region can be considered. By varying the length, width, distance, or otherwise different cooling fins, an asymmetrical envelope shape can be achieved. In particular, this can be an asymmetrical, rotationally asymmetrical, axially asymmetrical, or otherwise non-symmetrical envelope shape.

[0058] The actual cross-section of the first region can also be considered here. This, too, can have an asymmetrical shape due to the cooling fins, which differ in length. In particular, the cross-section can have an asymmetrical, rotationally asymmetrical, axially asymmetrical, or otherwise deviating from a symmetrical shape.

[0059] The cross-section of the first region can be larger than the cross-section of the second region. The cross-section should be determined essentially perpendicular to the longitudinal extent of the connecting element. A larger cross-section is associated, among other things, with an increased material volume and thus with an increased thermal capacity of the connecting element.

[0060] The cross-section of the first region of at least one of the connecting elements can be substantially constant along the longitudinal axis of the connecting element. The cross-section of the second region of at least one of the connecting elements, in particular of the connecting element, can be substantially constant along the longitudinal axis of the connecting element.

[0061] A plug-in direction can be defined for a connecting element. This direction can, in particular, be defined essentially parallel to the longitudinal axis of the connecting element and extend from the first region to the second region of the connecting element.

[0062] The first fastening element can be arranged in the first end face of the connecting element.

[0063] The first fastening element can, in particular, be shaped as a first recess. This can be suitable for receiving a connecting bolt. The first recess can extend parallel to the longitudinal axis of the connecting element in the direction of the central region of the connecting element. The first recess can have a substantially round cross-section; the cross-section can also be elliptical, angular, in particular triangular, square, pentagonal, or polygonal.

[0064] The cross-section of the first recess can be substantially constant along the longitudinal axis. The cross-section can also taper, in particular linearly, along the longitudinal axis towards the central region of the connecting element, so that the cross-section decreases linearly with increasing penetration depth of the first recess into the first region of the plug-in connector. The cross-section of a first recess can decrease uniformly on all sides perpendicular to the direction of extension of the first recess, for example perpendicular to the longitudinal axis of the connecting element. The cross-section can also decrease more sharply in one direction perpendicular to the longitudinal axis than in another direction. In particular, an asymmetry of the first recess can be achieved in this way, which only allows insertion of a correspondingly shaped bolt in one angular position around the longitudinal axis of the connecting element.

[0065] In a preferred embodiment, the first recess is conically shaped. For example, a blind hole, particularly one with an internal thread, can be provided as the first fastening element. The blind hole can extend from the end face into the connecting element.

[0066] A blind hole can also be provided in the first recess of at least one of the connecting elements. In particular, a thread can be provided in the blind hole. The blind hole can end in the first region. In some cases, it is also possible for the blind hole to extend into the second region. The blind hole, in particular with a thread, enables a secure screw connection of a connecting element, such as a connecting bolt, in the first recess. A high contact pressure between the bolt and the first recess can be achieved. This makes it possible to create a particularly low-resistance transition between a connecting bolt and the connecting element.

[0067] As an alternative to a recess, the first fastening element can also be a bolt, a threaded bolt, and / or an eyelet, or another fastening element, particularly one that points away from the end face. The fastening element can, for example, extend in the longitudinal direction of the connecting element.

[0068] A connecting element can be attached to the connecting element. For example, the connecting element can be a connecting bolt. The connecting element can also be, for example, a busbar and / or a cable lug. In particular, the first region of the connecting element can serve to connect a connecting element to it. If, for example, the connecting element has a recess with an internal thread, a connecting element having a through-hole can be connected to it, in particular screwed.

[0069] The connecting element can be connected to the connecting element in various ways. These include, as examples above, a force-fit connection, for example, by means of a screw connection. A material-fit connection is also possible, for example, by welding, soldering, or other material-fit joining methods.

[0070] In particular, in combination with a tapered, in particular conical recess, a likewise tapered, in particular conical connecting bolt can be permanently and firmly connected in the recess with good conductivity by means of the thread in the blind hole and a screw.

[0071] In a preferred embodiment, the connecting element has a second fastening element on its second end face.

[0072] The second fastening element can, for example, be a second recess. The second recess can be provided on the connecting element without the presence of the first recess described above. The second recess can taper, in particular, towards the central region. The second recess can also have a substantially constant cross-section along the longitudinal axis of the connecting element. The second recess can also have a thread, in particular an internal thread, for example on the inner circumferential surface of the second recess. In a further embodiment, at least one or more spring contacts can be provided, in particular in the second recess.

[0073] The second fastening means can, for example, be a bolt, threaded bolt, or similar, as an alternative to a second recess. In particular, the second region itself can function as a bolt.

[0074] The second region of at least one of the connecting elements can, for example, be shaped as a pin.

[0075] The second region of at least one of the connecting elements can be shaped as a bushing, in particular as a sleeve with a base. For example, the bushing can have an opening. The opening can be shaped as the second recess described above.

[0076] For example, a guide tip can be arranged on the second region, in particular the second end face. A guide tip can extend beyond the second end face in the direction of the longitudinal axis of the connecting element. The guide tip has a smaller diameter than the region of the second region on the side of the end face facing away from the guide tip. In particular, the guide tip can have an elevation, in particular a thickened portion and / or a depression, in particular a circumferential thickened portion and / or depression. A thickened portion and / or depression can serve to fasten an element to the guide tip.

[0077] In particular, a cap made of a non-conductive material can be arranged on the front end of the second region, in particular on the guide tip. This cap can in particular be arranged in a force-fitting and / or form-fitting manner on the second region, in particular on the guide tip. In particular, a recess and / or thickening of the guide tip can engage in a thickening and / or recess in the cap. The cap can be formed, for example, from plastic, silicone and / or another non-conductive material. In particular, the cap can have, at least in the transition to the second region, substantially the same cross-section as the region of the connecting element adjacent to the cap. This can prevent an edge at the transition between cap and connecting element. The cap can also have a smaller cross-section than the second region of the connecting element in the region of the connecting element that borders the cap.The end face of the cap facing away from the connecting element can be substantially flat, but a rounded end face shape can also be provided. The connector in question can function as both a plug and a socket. Both the first and second regions can be shaped as a recess and / or as a plug-in element.

[0078] According to one embodiment, the first region of at least one of the connecting elements can be extruded and / or pressed. In this case, for example, the cross-sectional shape of the first region of the connecting element can be defined. In this way, for example, a cross-section with one or more cooling fins can be achieved.

[0079] The production of a region, in particular the first region, of at least one of the connecting elements in this manner enables a particularly advantageous manufacturing method. It was recognized that the first region requires little or essentially no variation in the cross-section along the longitudinal axis of the connecting element. Accordingly, a manufacturing method as mentioned above is suitable for inexpensively producing a first region with a complex cross-section that is essentially constant along the longitudinal axis of the connecting element.

[0080] In a preferred embodiment, the second region of at least one of the connecting elements can be cast, deep-drawn and / or cold-extruded.

[0081] In particular, it was recognized that the second region of the connecting element must regularly be able to be connected to the standardized connection geometry of charging plugs. Therefore, the second region of the connecting element often has to have a complex shape that can change along the longitudinal axis of the connecting element. Extrusion or bulging, which is suitable for the first region, is therefore less suitable for the second region of the connecting element. Instead, one of the manufacturing methods mentioned above can be used to realize the complex shape. The material of the second region is also often chosen to be harder than that of the second region. For example, the second region can be made of copper and the first region of aluminum.Even for such hard materials, the methods mentioned above for the second area are more suitable than those mentioned for the first area.

[0082] In one embodiment, the first region and the second region of at least one of the connecting elements can be integrally connected to the first region of the connecting element. In particular, the connection between the first and second regions of the connecting element can be realized by means of a welding zone. The welding zone can, in particular, be a friction welding zone, in particular a rotary friction welding zone and / or an ultrasonic welding zone, and / or a resistance welding zone.

[0083] The material-to-material, in particular welded, connection between the first and second regions of the connecting element ensures particularly good thermal and electrical conductivity between the two regions. Thermal conductivity is particularly important because heat generated in one of the two regions, for example the second region, must be transported to the other of the two regions, for example the first region. Heat transport within the connecting element enables increased overall heat absorption capacity. Heat transport between different regions of the connecting element can also be particularly advantageous if one region is particularly suitable for dissipating heat. For example, the first region can be particularly suitable for dissipating heat into the environment due to an increased cross-section or cooling fins.If heat is generated in the second area, it must reach the first area as unhindered as possible to be dissipated there. The material connection between the two areas makes this possible with particularly low thermal resistance and is therefore particularly beneficial for the function of the connecting element in question. It was recognized that a two-part production from different materials is surprisingly more cost-effective than a one-piece production from a continuous solid material. It was recognized that often at least one of the two areas of the connecting element takes on a simple shape in itself. Thus, at least for this one area, a very cost-effective production as a mass product can be chosen.Surprisingly, the additional welding step is more than offset by the simplified production of the connecting element sections, which now have to be created separately.

[0084] The first and / or the second region of at least one of the connecting elements can be formed from a solid material.

[0085] The second region of at least one of the connecting elements can have, at least in part or entirely, a smaller cross-section than the first region of the connecting element.

[0086] A central axis can be defined for a region of the connecting element in question. This can, for example, run parallel to the longitudinal axis of the connecting element. In particular, the central axis can run through a center and / or near a center of at least some of the cross-sections of the respective region of the connecting element. The cross-section is a section perpendicular to the longitudinal axis of the connecting element and / or perpendicular to the longitudinal axis of the respective region of the connecting element whose cross-section is being determined. For example, the center of the cross-section can be defined as the geometric center of mass of the cross-section.

[0087] The center of the cross-section can also be determined, for example, as the center of the cross-section's envelope. For example, if the first region includes cooling fins, the center axis can be shifted with changes in the cooling fin length.

[0088] A central axis can be defined for the first area and also for the second area of ​​the connecting element.

[0089] The second area can be centrally connected to the first area.

[0090] For example, the central axis of the first region and that of the second region can substantially coincide with each other. The second region can also be arranged eccentrically on the first region. This can mean, for example, that the central axis of the second region is spaced apart from the central axis of the first region, in particular perpendicular to the central axis of at least one of the regions and / or perpendicular to the longitudinal axis of the plug pin and / or one of the regions of the plug pin.

[0091] If the first region has cooling fins, these can, for example, be shorter on the side of the first region to which the second region is displaced than on other sides of the first region. Cooling fins can also be arranged only on the side of the first region farther away from the second region. In this way, the dissipation of heat to the side farther from the second region can be controlled.

[0092] In one embodiment, in at least one of the connecting elements, the first fastening element, for example the first recess arranged in the first end face, can be arranged eccentrically to the central axis of the first region.

[0093] The recess in the first region of a connecting element can therefore also be arranged eccentrically to the central axis of the first region in the first region of the connecting element. In this way, similar to the eccentric positioning of the second region on the first region, adaptation to a predetermined distance between connecting elements such as connecting bolts can be achieved. Elements possibly positioned in the recess can also be adjusted in their distance from one another. In particular, the recess of at least one connecting element can be offset eccentrically outwards in the first region, so that it has a greater distance from another connecting element of the charging cable connector than it would have with a central arrangement.

[0094] The recess and the second region can be offset in substantially the same direction relative to the center axis of the first region. They can also be offset in different, particularly opposite, directions. For example, the second region of a connecting element can be brought closer to another connecting element of the charging cable connector due to its eccentric arrangement at the first region, while the recess is spaced apart from the other connecting element due to its eccentric arrangement at the first region of the connecting element.

[0095] The first region of the connecting element can have a further end face in addition to the first end face. This further end face can be oriented substantially away from the first end face. The further end face points toward the second region. The further end face can be substantially flat. A surface of the further end face that deviates from a flat shape is also possible, for example, a rounded shape, a tapered shape, in particular a conical, stepped and / or gable-roof-shaped taper, or another surface shape of the further end face.

[0096] In one embodiment, at least one of the connecting elements is at least partially coated. In particular, a metallic coating can be advantageous, for example, to prevent contact corrosion, reduce contact resistance, and / or make the connector more durable. For example, a connecting element can be coated with silver, gold, copper, aluminum, nickel, and / or other metals and / or alloys thereof. The coating can cover the connecting element essentially completely or can be applied only to selected areas. For example, a coating can be applied in the first recess and / or in the second area of ​​the connecting element. It is also possible to provide a plug pin with a double coating, at least in some areas, for example with an inner nickel layer and an outer silver layer.

[0097] In one embodiment, the second region is silver-plated under nickel, while the first region is merely silver-plated.

[0098] In one embodiment, the coating of at least one of the connecting elements is arranged only on the second region of the connecting element. The connecting element can also be coated substantially completely.

[0099] For example, the second region may be formed of copper or a copper alloy and coated with a coating, for example a silver coating, for example a nickel-plated silver coating.

[0100] The first area may be free of coating or coated with a different coating than the second area.

[0101] For example, the first region may be coated only in the area of ​​a fastening element. For example, the first region may be coated in the region of the first recess. The remaining regions of the first region may be free of coating.

[0102] The second region of at least one of the connecting elements can, for example, at least partially have a round cross-section, an oval, elliptical, angular, in particular triangular, square, polygonal, or otherwise shaped cross-section. The cross-section of the second region can be substantially constant along the longitudinal axis. The cross-section of the second region can also vary. In particular, the cross-section of the second region can increase, for example, toward the central region, in particular in the central region, for example, increasing in steps.

[0103] In particular, the cross-section of the second region can have a raised cross-section in the central region, at the transition to the first region. This increases the mechanical stability of the transition. Furthermore, a recess, for example a circumferential groove, can be provided in the central region. In particular, a seal, for example a sealing ring, can be provided around the second region, particularly in the region of the raised cross-section, particularly in the circumferential groove.

[0104] The connector in question may comprise a housing.

[0105] The housing can be formed from a non-conductive material. For example, the housing can be formed from a plastic, in particular a plastic suitable for high temperatures and / or with high thermal conductivity (high-temperature plastic). For example, polyamideimide, polysulfone, polyethersulfone, PA6GF15, UL94, or a similarly heat-resistant plastic can be used. The housing can also be formed at least partially from other non-conductive materials such as ceramic or glass.

[0106] The housing of the charging cable connector and / or the housing of the charging socket can be formed in one piece, for example, by casting and / or injection molding. It is also possible for the respective housing to be constructed from multiple parts. The individual parts can, for example, be screwed, glued, welded, or attached to one another and / or to other elements in another way. Any seals arranged on the charging cable connector and / or the charging socket can, for example, be manufactured together with other parts of the respective housing using a two-component injection molding process. Seals can also be arranged on the housing as separate components.

[0107] The charging cable connector may comprise a single connecting element. The charging cable connector may also have at least two connecting elements.

[0108] The connecting elements of the charging cable connector can be fixed in the housing relative to one another and / or relative to the housing. In particular, the connecting elements can be fixed such that the longitudinal axes of at least two connecting elements are substantially parallel to one another. The housing can fix the plug pins in such a way that they cannot move relative to one another without deforming and / or damaging the housing.

[0109] In the case of an eccentric arrangement of the second region on the first region of the at least one connecting element, it is possible, particularly in an arrangement comprising two or more connecting elements, for the center axes of the first regions to be further apart than the center axes of the second regions. The center axes of the second regions can also be further apart than the center axes of the first regions.

[0110] A distance between two axes, especially central axes, can be defined as the shortest possible connection between two axes.

[0111] The center axes of the second regions of at least two connecting elements can both be spaced apart from the center axis of the first region of the respective connecting element. Only the second region of one of the connecting elements can be arranged eccentrically on the first region of the connecting element, while the other connecting element(s) have a first and a second region, each with a substantially identical center axis. The center axes of the first regions and the second regions of the at least two connecting elements can lie substantially in a common plane.

[0112] The center axes of the second regions may be spaced apart from one another by a smaller distance than the center axes of the first regions of the at least two connecting elements.

[0113] The central axis of the first region and that of the second region can be parallel to each other. The two central axes can also be tilted relative to each other.

[0114] An eccentric arrangement of the second region on the first region enables not only better heat dissipation and stress resistance, but also, in particular, a relative positioning of the center axes of the two regions (the first and the second) to each other. In particular, this can, for example, partially accommodate two different mating geometries. One mating geometry can be connected on the side of the second regions, another on the side of the first region of the connecting elements. An eccentric arrangement can compensate for different distances between connection points on the side of the first region and the second region.

[0115] The geometric distances within the charging cable connector can also be influenced by the eccentric arrangement of the second region on the first region. By means of the eccentric arrangement of the second region on the first region, the second region of a first connecting element can be brought closer to or further away from at least one other connecting element without the relative position of the first regions of the connecting elements changing. The same applies conversely to the position of the second regions of the connecting elements. The second region of a first connecting element can, for example, be spaced as far as possible from the second connecting element, in particular from the second region of the second connecting element, by means of an eccentric arrangement.The second region of a first connecting element can also be brought as close as possible to the at least one further connecting element of the connector.

[0116] Likewise, it is possible to vary the distance between the first regions by eccentrically arranging the second region relative to the first region, while maintaining a substantially constant distance between the first regions. The first regions can also be brought closer together or spaced apart in this way.

[0117] In a preferred embodiment, the second regions of the at least two connecting elements are each arranged eccentrically in the direction of the other connecting element(s). In this way, the first regions are spaced as far apart as possible, given a given distance between the second regions. In other words, the second regions are spaced as closely apart as possible, given a given distance between the first regions.

[0118] The at least two connecting elements are spaced apart from one another in the charging cable connector. In particular, the connecting elements are spaced apart from one another substantially perpendicular to the longitudinal axis of at least one of the connecting elements.

[0119] The longitudinal axes of the connecting elements are essentially parallel to each other. The insertion directions of the connecting elements can also be essentially parallel to each other. The insertion directions and / or longitudinal axes can also be tilted relative to each other.

[0120] The eccentric arrangement of the second regions of the at least two connecting elements allows the second regions of the connecting elements to approach one another while maintaining the same distance between the first regions. The eccentric arrangement also allows the second regions to be spaced apart from one another. For a given connector face, the smaller distance between the center axes of the second regions compared to the distance between the center axes of the first regions can ensure that heat can be dissipated as effectively as possible via the first regions. The spacing of the first regions leads to little heat build-up between the connecting elements. The recesses in the first regions can also be spaced apart from one another as far as possible, which further leads to a spatial distribution of warm elements.

[0121] If cooling fins are arranged on the first region of at least one of the connecting elements, they can only be arranged on one side, which faces away from the at least one further connecting element. The side of the first region which faces the at least one further connecting element can therefore be free of cooling fins. The cooling fins of the first region can also be arranged essentially on all sides of the first region. In this case, for example, the cooling fins which face away from the at least one further connecting element can be more numerous, longer, have a larger surface area and / or a larger volume than the cooling fins which face away from the at least one further connecting element. The cooling fins can also, for example, be essentially the same length.

[0122] If at least two connecting elements have cooling fins in their respective first region, these can be designed to be more numerous, longer, have a higher surface area and / or a higher volume on the side of the first region directed away from the at least one further connecting element than on the side which points towards the respective other connecting elements.

[0123] In the case of longer, larger-area and / or larger-volume cooling fins on a first side than on a second side, this can mean here and in all further embodiments that the cooling fins are averaged over the respective side and / or also longer and / or larger in total over the respective side. The two sides of the first region of a first connecting element can be defined by placing a plane through the central axis of the first region, which is aligned parallel to the central axis and perpendicular to the distance vector from the central axis of the first region of the first connecting element to the central axis of a first region of a second connecting element. The plane defined in this way divides the first region of the first connecting element into a side facing the second connecting element and a side facing away from the second connecting element.In the cross-sectional view of the first area of ​​the connecting element, these two sides are each circular sections of 180°, which do not overlap each other.

[0124] For example, cooling fins can also be arranged only on the side facing away from the at least one further connecting element.

[0125] By varying the cooling fin distribution between different sides of the first region of at least one of the connecting elements, heat dissipation can be controlled in the desired direction. In the case of multiple connecting elements, heat can be dissipated in particular in directions away from the other connecting elements.

[0126] The cooling fins of at least one of the connecting elements can therefore be arranged asymmetrically around the first region of the connecting element. Asymmetrical can in particular mean point asymmetrical, rotationally asymmetrical, axially asymmetrical or asymmetrical in some other way. Here and in the remainder of the description, a specific "A" symmetry such as point asymmetry indicates that the corresponding symmetry is not present, i.e., for example, no point symmetry. This serves to optimize heat transport out of the charging cable connector in question. The first and / or second end faces of the connecting elements can essentially be flush with one another in the longitudinal direction. The end faces can therefore be aligned with one another in a direction perpendicular to the longitudinal axis, central axis and / or plug-in direction of at least one of the connecting elements.The connecting elements can also be offset from each other along the longitudinal axis.

[0127] The connecting elements can, in particular, be of equal length. Different lengths are also possible. For example, the first regions of at least two connecting elements can have different lengths, in particular such that the recesses are offset from one another along the longitudinal axis, while at least some of the remaining regions of the connecting elements, for example, the second end faces, are not offset from one another along the longitudinal axis.

[0128] In one embodiment, the at least two connecting elements of the connector are substantially identical in shape. In another embodiment, the connecting elements are constructed essentially mirror-symmetrically to one another. The imaginary mirror surface on which the connecting elements are mirrored can, in particular, run parallel to the longitudinal direction of at least one of the connecting elements.

[0129] The housing can fix the at least two connecting elements to one another. For this purpose, the housing at least partially encloses the connecting elements. The housing can in particular engage the outer circumferential surfaces of the first regions of the connecting elements. The housing can bear against the circumferential surfaces of the first regions of the connecting elements. In particular, the housing encloses the first regions of the connecting elements essentially over their entire surface. If the circumferential surfaces have elevations and / or depressions, the housing can in particular engage in the depressions. The circumferential surfaces of the first regions offer a large access area for the housing. Since the first region is preferably contacted with another current-carrying element via the recess, the circumferential surface also does not fulfill an electrically conductive function and can be covered with the housing.In addition to the mechanical fixation of the connecting elements, this also serves to electrically insulate the first area.

[0130] In particular, the housing serves to electrically insulate the connecting elements from one another.

[0131] The cooling fins can improve the anchoring of the connecting elements in the housing. This is already achieved by the increased surface area of ​​the casing. The engagement of the housing in the spaces between the cooling fins further improves the quality of the connection between the connecting elements and the housing.

[0132] The housing of the charging cable connector can, as already mentioned above, have openings. These enable at least contact to be made with the recess in the end face of the first region of at least the connecting elements. In one embodiment, the housing has an opening in the region of the first end face of at least one of the connecting elements. In particular, the first end face can be completely exposed by an opening in the housing. In one embodiment, the housing is essentially flush with the first end face of at least one connecting element. It is also possible for the housing to project beyond the first end face in the longitudinal direction. The first end face can also be essentially completely covered by the housing, so that only access remains for receiving at least one connecting element.This can have the advantage that after connecting a connection element, for example a connection bolt, few conductive surfaces are openly accessible in the recess.

[0133] An opening must also be provided in the housing, which allows contacting of at least parts of the second region of the connecting element. The housing can have an opening for at least one, preferably for all, connecting elements on the side of the housing and / or of the respective connecting element opposite the first end face. This allows contacting of the second region of the connecting element. As already highlighted above, a further end face of the first region can be identified, which is different from the first end face of the connecting element. This is an end face which faces the second region of the respective connecting element, to which the first region belongs. In some embodiments of the housing, this further end face is also at least partially exposed through an opening in the housing.

[0134] In particular, the housing can be substantially flush with the further end face of the first region. It is also possible for the housing to extend at least partially beyond the further end face in the longitudinal direction toward the second region. It is also possible for the further end face of the first region to be substantially completely covered by the housing.

[0135] The charging cable connector can form a receptacle for a charging plug. The charging cable connector can also form part of a charging plug. For example, such a charging plug can be a Mode 2, Mode 3, Type 1, or Type 2 plug. In particular, the plug can have connections for direct current charging. For example, the plug can be a Combined Charging System (CCS), CHAdeMO, a Tesla® Supercharger plug, or another plug with direct current contacts.

[0136] It is understood that the first area and equally the second area can each serve as a plug-in element and / or as a receptacle.

[0137] A further aspect relates to a method according to claim 35 for producing a connecting element for a charging cable connector.

[0138] The method comprises, in particular, providing a first region made of a first metal material. The first region can, in particular, have been obtained beforehand by means of extrusion and / or extrusion. The manufacturing method for the charging cable connector can, in particular, also comprise the step of extrusion and / or extrusion. The semi-finished product obtained in this way can, for example, be a long strand with, for example, a constant cross-section along its length. For example, the semi-finished product can be formed from aluminum. The first region can, in particular, be cut to length; for example, the first region can have been cut to length from a semi-finished product produced as described above; the cutting to length can be part of the manufacturing method. The cutting to length can, for example, be achieved by sawing, punching, laser cutting, evaporation, or similar methods.

[0139] In particular, at least one or more cooling fins of the first region can be obtained through extrusion and / or compression molding. For example, a semi-finished product obtained in this way may already have the cooling fins.

[0140] The method further comprises, in particular, providing a second region made of a second metal material. The second region was, in particular, previously obtained by casting, deep drawing, and / or cold extrusion. This manufacturing process for the second region can be part of the manufacturing method.

[0141] The first and / or second area can be further coated. The coating of the first and / or second area can be carried out independently of the other area.

[0142] The method further comprises, in particular, a material-to-material joining of an end face of the first region to an end face of the second region. The material-to-material joining may, in particular, be a welding process. The end face of the first region at which the joining is performed may, in particular, be the further end face of the first region.

[0143] For example, the welding can be achieved by friction welding. In particular, rotational friction welding can be used as a method, wherein, in particular, the second region is set in rotation and is rotationally friction welded to the first region. The first region can, for example, be fixed in place. In a further embodiment of the method according to the present aspect, the welding is achieved by ultrasonic welding.

[0144] Alternatively or additionally, welding can be carried out by resistance welding.

[0145] Any coating of at least part of the connecting element can be performed before joining. Alternatively or additionally, the coating can be performed after joining. For example, it may be advantageous to coat the second area before the connection to the first area is established.

[0146] In one embodiment, the second region can be made of a copper material, in particular copper or alloys. In this case, the second region can be silver-plated, for example, with a nickel-plated silver coating.

[0147] Coating before joining the two areas of the connecting element has the advantage that selective coating of one of the two areas is possible without having to mask the other area.

[0148] The joined connecting element can also be coated entirely, particularly silver-plated. For example, the second area can first be coated with a first layer, such as nickel. After joining, the entire connecting element can then be silver-plated.

[0149] The individual steps mentioned can be performed in the above-mentioned order. The steps of the method can also be performed in a permuted order, one after the other and / or at least partially simultaneously. Before and / or after joining the first and second regions, a first and / or a second recess can be introduced into the first and / or second regions.

[0150] The method may also include the step of enclosing at least one connecting element or several connecting elements, for example two connecting elements, in a housing. For example, the connecting elements can be encapsulated and / or overmolded.

[0151] A further aspect relates to a charging socket according to claim 39.

[0152] The charging socket can have a connector receptacle, which can be arranged in particular on the rear side of the charging socket. The connector receptacle can be suitable for inserting the charging cable connector. The connector receptacle can comprise a recess in the charging socket, in particular in the housing of the charging socket. The connector receptacle can in particular be at least partially substantially cross-sectionally adapted to a charging cable connector.

[0153] The charging socket can also include a support surface for the charging cable connector. The connector can rest at least partially on the support surface. The support surface can be arranged, for example, on the housing of the charging socket. The support surface can be arranged, for example, circumferentially around the plug pins and / or the connector receptacle. The support surface can also be arranged at least partially on the collar.

[0154] Retaining means for the charging cable connector can be provided on the charging socket, for example, positive and / or non-positive retaining means, for example, hooks, threads for screws, in particular threads embedded in the housing of the charging socket, in particular made of a metal material, or similar retaining means. The retaining means can be arranged in particular in the region of the connector receptacle, for example in the connector receptacle or in an area around the connector receptacle. The retaining means can serve to connect a charging cable connector to the charging socket. For example, the connector can be fastened to the charging socket by means of at least one, preferably two, three, or four or more screws.

[0155] The charging cable connector can in particular be connected to the charging socket in a force-locking and / or form-locking manner.

[0156] At least one seal can be arranged on at least parts of the connector receptacle and / or the support surface. For example, the seal can be arranged in a closed shape, such as a ring, rectangle, oval, or other closed shape, on the connector receptacle and / or the support surface. The seal can enclose at least part of the connector receptacle. The seal can be made, for example, from an elastic material, in particular from a plastic, rubber, silicone, or similar materials. Such a seal can be arranged on the connector.

[0157] The charging socket in question comprises at least one receptacle for a charging plug. The receptacle is located on the front. The charging plug can, for example, originate from a charging station. This can be a Mode 2, Mode 3, Type 1, or Type 2 plug. In particular, the plug can have connections for direct current charging. For example, the plug can be a Combined Charging System (CCS), CHAdeMO, a Tesla® Supercharger plug, or another plug with direct current contacts.

[0158] A further aspect relates to a system according to claim 41. The system comprises a physical charging socket. This can be connected to a physical charging cable connector. In particular, the charging cable connector can be arranged at least partially in the charging socket, in particular in the connector receptacle of the charging socket. In particular, the connector can be arranged in the charging socket such that at least one of the at least two second regions of the connecting elements are at least partially arranged in the receptacle of the charging socket. In particular, the charging cable connector can be in contact with the charging socket all the way around at least one of the connecting elements, for example on a support region of the charging socket. The housing of the charging cable connector can contact the charging socket directly and / or a seal can be arranged between the two, via which seal the charging cable connector indirectly contacts the charging socket.The charging socket and charging cable connector can be connected to each other with a force-locking and / or positive fit. In particular, the housing of the charging cable connector can be connected to the charging socket, especially to the housing of the charging socket. In particular, the two can be screwed together.

[0159] The charging socket, the charging cable connector, and / or the system in question may be suitable for connection to a connector. The connector may, for example, be located on the back of the charging socket. The connector may also be located at least partially within the charging socket.

[0160] The connecting part can in particular comprise a busbar. The busbar in particular has a substantially rectangular cross-section. The cross-section can have two opposing and substantially parallel broad sides and two narrow sides arranged substantially perpendicularly thereto, substantially parallel to each other and opposite each other. The busbar at least partially has a longitudinal axis which is oriented substantially perpendicular to both the narrow and broad sides. The broad side is wider than the narrow side perpendicular to the longitudinal axis. The busbar can, for example, comprise a connecting bolt. The connecting bolt can in particular engage with the first region of at least one of the connecting elements. For example, the connecting bolt can have a shape congruent with the first recess of at least one of the connecting elements.For example, the connecting bolt can be tapered, particularly so that the connecting bolt is conical in shape. The connecting bolt can, for example, have a through hole in the longitudinal direction. The connecting bolt, and thus in particular the busbar, can be screwed to the connecting element through the through hole.

[0161] The connecting part, in particular the busbar, can also have a through hole, for example. For example, the busbar can be screwed to the connecting element using a screw. For this purpose, the connecting element can, for example, have a receptacle with an internal thread.

[0162] The connecting part can also be a cable lug, for example, in particular with a through hole.

[0163] The subject matter is explained in more detail below with reference to a drawing showing exemplary embodiments.

[0164] Fig. 1a,b a charging socket with charging cable connector according to an embodiment in an isometric view from two viewing angles;

[0165] Fig. 2 shows a charging socket with a charging cable connector according to an embodiment in a lateral sectional view; Figs. 3a-e show various connecting elements and charging cable connectors according to embodiments;

[0166] Fig. 4 shows an isometric view of an object connecting element according to an embodiment;

[0167] Fig. 5 shows a charging cable connector according to an embodiment;

[0168] Fig. 6a-c sectional views of objective connecting elements according to embodiments;

[0169] Fig. 7a-c schematic representation of the two sides of the cross section of the first region of a subject connecting element according to an embodiment and exemplary definition of the cooling fins.

[0170] Fig. 1a shows a charging socket 400. This comprises a receptacle 410. A charging cable connector 300 with two connecting elements 100 and a housing 200 is arranged in the charging socket 400. The housing 200 can have a cross-section adapted to the connector receptacle 412. The housing 200 of the charging cable connector in 300 can rest against the charging socket 400 and in particular be connected thereto. For example, these two elements can be connected to one another in a force-fitting and / or form-fitting manner. For example, screws, as shown, can hold the charging cable connector 300 to the charging socket 400. The second region 120 of the connecting elements 100 projects into the receptacle 410. The receptacle 410 can serve to connect a charging plug, wherein at least one of the plug pins 100 serves as a contact pin for the charging plug.

[0171] The charging cable connector 300 can protrude from the housing of the charging socket, as shown by way of example in Fig. 1b. For example, this can be realized by means of a collar 420. Fig. 2 shows an actual charging socket 400 with a charging cable connector 300 in a sectional view along section line 111 in Fig. 1a. Two connecting elements 100, 100* can be seen. These have a second region 120, a first region 110, a recess 130, as well as a front 122, a rear 112, and a further 114 end face.

[0172] A blind hole 132 is arranged in the recess 130. A thickening can be seen on the second region 120 in the transition to the first region 110 of the connecting element 100. This thickening is designed in two stages with a first raised cross-section and a second raised cross-section. In particular, the first raised cross-section is larger than the cross-section of the remaining second region 120 in the plug-in direction, and the second raised cross-section is larger than the first raised cross-section and thus also higher than the cross-section of the remaining second region 120 in the plug-in direction. A groove 129 is arranged around the second region 120 in the transition between the second region 120 and the first region 110. This groove can accommodate a sealing ring, for example.

[0173] The receptacle 410 of the charging socket 400 can also have a rear wall 430. The connecting elements 100, 100' can be passed through this. For example, as shown, the sealing ring can be arranged around the second region 120 between the connecting element 100, 100' and the charging socket 400, in particular the bottom 430 of the receptacle 410 of the charging socket, in particular with a press fit.

[0174] Fig. 3 shows various embodiments of the subject connecting elements 100, 100' in single and double versions. The sectional views shown show the cross section of the first region 110.

[0175] Figure 3a shows connecting elements 100, 100', which have a star-shaped, rotationally symmetrical cross-section of the first region 110. These are surrounded by a housing 200. The envelopes 160, 160' are shown by dashed lines. As can be seen, the outline of the cross-section of the two connecting elements 100, 100' is longer than the outline of the envelopes 160, 160'. The cross-section is thus at least partially concave. The respective cooling fins 170 are essentially triangular in shape and taper, in particular, toward their end facing away from the connecting element 100, 100'.

[0176] It can also be seen that the housing 200 is arranged in the spaces between the cooling fins 170, for example, the housing 200 may have penetrated into the spaces.

[0177] Figure 3b shows an alternative cross-section in which the cross-section of the connecting elements 100, 100' is not symmetrical. In the case shown, this is due to the different lengths of the cooling fins 170. In the arrangement of two connecting elements 100, 100', the cooling fins on the side of the connecting element 100, 100' facing the other connecting element 100, 100' are shorter than the remaining cooling fins 170. In this way, a directed heat dissipation from the connecting element 100, 100' into the environment can be ensured. In particular, the heat can be conducted away from the other connecting element 100, 100'.

[0178] Figure 3c shows another cross-sectional configuration of the connecting elements 100, 100'. In this configuration, the cooling fins 170 are arranged only in a partial area of ​​the circumference of the connecting elements 100, 100'. In the present case, the circular arc along which the first area 110 is equipped with cooling fins 170 measures approximately 180°. In the arrangement with two connecting elements 100, 100', the sides without cooling fins face the other connecting element 100, 100'.

[0179] Figure 3d shows a further embodiment of the cross-section of the connecting elements 100, 100'. Here, the cooling fins 170 are tapered at their end pointing away from the respective connecting element 100, 100'. Cooling fins are also located along the entire circumference of the respective connecting elements 100, 100*. In this case, no side of a connecting element 100, 100' is free of cooling fins, as is the case, for example, in the embodiment shown in Figure 3c. The cooling fins 170 vary in length and are shorter, in particular, on the side of the respective connecting element 100, 100' facing the other connecting element 100, 100' than on the side facing away from the other connecting element 100, 100'.

[0180] Figure 3e shows a further profile in which the cooling fins 170 are substantially rectangular in shape and are arranged uniformly over the entire circumference of the first region 110 of the connecting element 100.

[0181] Figure 4 shows an isometric view of the connecting element 100 in question. The first region 110 has a plurality of cooling fins 170. The lateral surface 111 is thus characterized by depressions and elevations. The cooling fins extend along the longitudinal direction 150. In the illustrated embodiment, the cooling fins 170 extend along the entire length of the first region 110 of the connecting element 100. The cooling fins 170 increase the surface area of ​​the lateral surface 111 compared to a lateral surface 111 whose cross-section would correspond to the envelope of the cross-section as shown in Figure 4.

[0182] In the illustrated embodiment, the second region 120 of the connecting element 100 is arranged eccentrically on the first region 110. The second region 120 has a thickened portion at its end facing the first region 110. The second end face 122 is arranged at the opposite end. A recess 130 is arranged in the first end face 112 of the first region 110. This recess can also be arranged decentrally to the central axis of the first region 110. Figure 5 shows a charging cable connector 300 according to an exemplary embodiment. Two connecting elements 100, 100' are enclosed by a housing 200. The second regions 120 are positioned eccentrically on the first regions 110. The central axes of the second regions 120 are spaced closer to one another than the central axes of the first regions 110.In the embodiment shown, the cooling fins 170 on the sides of the connecting elements 100, 100' facing away from the respective other connecting element 100, 100' have an increased length compared to the sides facing the respective other connecting element 100, 100'. This promotes the dissipation of heat to the outside. In particular, an increased temperature is to be expected between the two connecting elements 100, 100', which is usually higher than the ambient temperature on the sides facing away from the respective other connecting elements 100, 100'. For this reason, heat transport to the sides of each of the at least two connecting elements 100, 100' facing away from the respective other connecting elements is promoted. This can be further promoted by selecting the length of the cooling fins.

[0183] Figure 6 shows various representations of the connecting elements 100.

[0184] Figure 6a shows an embodiment in which the second region 120 has a smaller diameter, in particular a smaller cross-section, than the first region 110. A fastening element 130 is arranged on the first end face of the first region 110. In the illustrated embodiment, this is a bolt 130, which may, for example, have a thread. The second region 120 is shaped, for example, as a bolt and / or a pin.

[0185] Figure 6b shows an embodiment of the subject connecting element 100, in which the second region 120 has substantially the same diameter, in particular the same cross-section, as the first region 110. In the embodiment shown, the fastening element 130 in the first end face is a second recess 130. The second region 120 comprises a recess 124. This can be configured, for example, to accommodate a plug, a connecting bolt, a pin, or the like. For example, the shown connecting element 100 can serve as part of a socket for a charging plug. A plug element of the charging plug can, for example, be inserted into the second recess 124 of the connecting element 100. Spring elements 125 can be arranged in the second recess 124, as shown.The spring elements 125 can exert contact pressure between a plug element inserted into the second recess 124 and the connecting element. In this way, the contact resistance between a plug element and the connecting element 100 can be reduced.

[0186] Figure 6c shows a further embodiment of the subject connecting element 100. In this embodiment, the cross-section and / or diameter of the second region 120 is larger than that of the first region 110. The second region 120 has a second recess 124. The first region 110 has a fastening element 130 in the form of a recess with an internal thread 130.

[0187] For example, a connection element 500 can be attached to the connecting element 100. In the illustrated embodiment, the connection element 500 is designed as a busbar 500. The busbar 500 includes a hole, in particular a through-hole 510. The busbar 500 can be connected to the connecting element 100 by means of a screw 520.

[0188] Figure 7 illustrates the characterization of the cooling fins 170 on the connecting elements 100,100*.

[0189] As shown in Figure 7a, in the case of two connecting elements 100, 100', one of the two connecting elements 100, 100', in particular its second region 120, can be separated into two regions by means of a plane A. The plane A is aligned in particular parallel to the central axis B of the respective connecting element 100, 100', in particular its first region 110, and extends through it. At the same time, the surface A is aligned perpendicular to the distance vector C between the central axis of the first region 110 of the connecting element 100' and the central axis of the first region 110 of the connecting element 100.

[0190] Figure 7b shows the cross-section of the two connecting elements 100, 100', in particular their first regions 110. The cross-section of the first region 110 of the connecting element 100' can be divided into two regions 180, 182 by means of plane A. In the example shown, the cooling fins 170 are arranged exclusively on the side 182 of the connecting element 100' facing away from the other connecting element 100. On the other hand, no cooling fins are arranged on the side 180 of the connecting element 100' facing toward the other connecting element 100.

[0191] Figure 7c shows one possible way of defining the cooling fins 170. For the cross-section of a first region 110 of a connecting element 100, an outer envelope 160, already known from the above explanations, can be defined. This is the smallest convex surface that encloses the entire cross-section of the first region 110. Similarly, a largest inner convex surface 162 can be defined, which can be arranged within the cross-section of the first region 110 of the connecting element 100. All sub-regions of the cross-section of the first region 110 that are not occupied by the largest inner convex surface 162 can be defined as cooling fins 170.

Claims

(Patent claims) Charging cable connector for high-voltage applications comprising at least one connecting element, wherein the connecting element has a first region extending from a first end face to a central region made of a first metallic material and a second region extending from a second end face to the central region made of a second metallic material, characterized in that the first metallic material is different from the second metallic material. ) Charging cable connector according to one of the preceding claims, characterized in that the first metallic material comprises aluminum or an aluminum alloy and the second metallic material comprises copper or a copper alloy, or the second metallic material comprises aluminum or an aluminum alloy and the first metallic material comprises copper or a copper alloy.A charging cable connector according to one of the preceding claims, characterized in that the cross-section of the first region of at least one of the connecting elements is at least partially larger than the cross-section of the second region of the connecting element. A charging cable connector according to one of the preceding claims, characterized in that the cross-section of the first region of at least one of the connecting elements has a longer outline than its enclosing and / or. the cross-section of the first area of ​​at least one of the connecting elements is shaped differently from a convex shape and / or is at least partially concave. 5) Charging cable connector according to one of the preceding claims, characterized in that the first area of ​​at least one of the connecting elements has at least one cooling fin or a plurality of cooling fins, wherein the cooling fins in particular run parallel to the longitudinal axis of the connecting element. 6) Charging cable connector according to one of the preceding claims, characterized in that the cooling fins extend in the longitudinal direction of the connecting element substantially along the entire length of the first area and / or that the cooling fins are arranged circumferentially around the cross-section of the first area. 7) Charging cable connector according to one of the preceding claims, characterized in that at least one or more or all of the cooling fins of at least one of the connecting elements taper towards their side pointing away from the first area or have a substantially constant width. 8) Charging cable connector according to one of the preceding claims, characterized in that the cooling fins of at least one of the connecting elements differ from each other in their length perpendicular to the longitudinal axis of the connecting element, in particular such that the first area has an asymmetric, in particular rotationally asymmetric, axially asymmetric and / or point-asymmetric cross-section. ) Charging cable connector according to any one of the preceding claims, characterized in that the cross-section of the first region of at least one of the connecting elements is substantially constant along the longitudinal axis of the connecting element and / or the cross-section of the second region of at least one of the connecting elements is substantially constant along the longitudinal axis of the connecting element. 0) Charging cable connector according to any one of the preceding claims, characterized in that the connecting element has a first fastening means, in particular a first recess, in particular a first recess tapering towards the central region and / or a first recess with a thread, on its first end face.1) A charging cable connector according to any one of the preceding claims, characterized in that a blind hole, in particular a threaded blind hole, is arranged in the first recess of at least one of the connecting elements, such that a screw can be guided through the recess into the blind hole and fastened there. 2) A charging cable connector according to any one of the preceding claims, characterized in that the first recess is conically shaped. 3) A charging cable connector according to any one of the preceding claims, characterized in that the connecting element has a second recess on its second end face, in particular one extending towards the central region. tapered second recess and / or a second recess with a thread and / or a second recess comprising spring contacts. 14) Charging cable connector according to one of the preceding claims characterized in that the first area of ​​at least one of the connecting elements is extruded and / or pressed, in particular together with the at least one cooling fin, and / or that the second area is at least cast, deep drawn and / or cold extruded, and / or that the first area and the second area are joined by a material bond, in particular by means of a weld zone, in particular a friction weld zone. 15) Charging cable connector according to one of the preceding claims characterized in that the first and / or the second area of ​​at least one of the connecting elements are formed from a solid material. 16) Charging cable connector according to one of the preceding claims characterized in that the second area of ​​at least one of the connecting elements has a smaller cross-section at least partially or completely than the first area. 17) Charging cable connector according to one of the preceding claims characterized in that the central axis of the second region of at least one of the connecting elements is arranged eccentrically to the central axis of the first region of the connecting element. A charging cable connector according to one of the preceding claims, characterized in that the first recess is arranged eccentrically to the central axis of the first region of the at least one connecting element in the first end face of the connecting element. A charging cable connector according to one of the preceding claims, characterized in that the second region of the connecting element adjoins a further end face of the first region of the connecting element, different from the first end face, which faces the second region. A charging cable connector according to one of the preceding claims, characterized in that the second region of at least one of the connecting elements is shaped as a pin and / or the second region of the connecting element has at least a partially cylindrical shape, or that the second region of at least one of the connecting elements is shaped as a socket, in particular as a sleeve with a base.A charging cable connector according to one of the preceding claims, characterized in that at least one of the connecting elements is at least partially coated, in particular with silver, gold and / or nickel, in particular with a lower coating of nickel and an upper coating of silver applied to the lower coating. A charging cable connector according to one of the preceding claims, characterized in that. the coating is arranged only on the second area of ​​the connecting element, or that the plug pin is substantially completely coated, and / or that the first area of ​​the connecting element is coated with a first material, for example silver, and the second area is coated with the first material and a second material, in particular silver-plated under nickel. ) Charging cable connector according to one of the preceding claims, characterized in that the cross-section of the second area of ​​at least one of the connecting elements is increased in the transition between the first and the second area in relation to the remaining cross-section of the second area, in particular in the area of ​​the transition at least one recess, in particular a groove at least partially circumferential, is arranged on the second area.A charging cable connector according to one of the preceding claims, characterized in that it comprises at least two connecting elements. A charging cable connector according to one of the preceding claims, characterized in that the at least two connecting elements are fixed relative to each other in the housing. A charging cable connector according to one of the preceding claims, characterized in that the at least two connecting elements are arranged relative to each other in the connector such that their respective longitudinal axes are substantially parallel to each other, in particular that the at least two connecting elements are fixed in the housing in such a manner. 27) Charging cable connector according to one of the preceding claims characterized in that the central axes of the second areas of the at least two The connecting elements have a smaller distance to each other than the central axes of the first areas of the at least two connecting elements. 28) Charging cable connector according to one of the preceding claims characterized in that the first area of ​​at least one of the connecting elements and / or both connecting elements has at least one or more cooling fins, wherein the cooling fins on a side of the connecting element facing away from the other connecting element are more numerous, longer and / or have a higher volume than on a side of the connecting element facing the other connecting element. 29) Charging cable connector according to one of the preceding claims, characterized in that the at least two connecting elements are spaced apart from each other perpendicular to the longitudinal axis of at least one of the connecting elements and / or the first and / or the second end faces and / or the further end faces of the at least two connecting elements are aligned perpendicular to the longitudinal axis of at least one of the connecting elements. 30) Charging cable connector according to one of the preceding claims, characterized in that at least two of the connecting elements have essentially the same shape and / or are essentially mirror-symmetrical to each other. 31) Charging cable connector according to one of the preceding claims, characterized in that the housing at least partially encloses the lateral surface of the first area of ​​the first connecting element and the lateral surface of the first area of ​​the second connecting element. 32) Charging cable connector according to one of the preceding claims, characterized in that the housing is formed from a non-conductive material, in particular from plastic, in particular from high-temperature plastic, in particular injection molded, in particular injection molded around the connecting elements. 33) Charging cable connector according to one of the preceding claims, characterized in that the housing rests on the outer surfaces of the first areas of the connecting elements, in particular rests substantially over the entire outer surface of the outer surfaces of the first areas of the connecting elements, in particular engages in the recesses, in particular in the spaces between the cooling fins on the outer surfaces. 34) Charging cable connector according to one of the preceding claims, characterized in that the housing has an opening in the area of ​​the first end face of at least one of the connecting elements and / or in the area of ​​the further end face of the first area of ​​at least one of the connecting elements. 35) Method for manufacturing a connecting element for a charging cable connector according to one of the preceding claims, comprising the steps Providing a first section made of a first metallic material, wherein the first section was in particular previously obtained by extrusion and / or cutting to length, Providing a second area made of a second metallic material, wherein the second area was previously obtained in particular by casting, deep drawing and / or cold extrusion, Material-bonded joining, in particular welding, of an end face of the first area with an end face of the second area. 36) Method according to one of the preceding claims, characterized in that at least one cooling fin is obtained on the first area by extrusion and / or compression. 37) Method according to one of the preceding claims, characterized in that the welding is carried out by means of friction welding, in particular by means of rotational friction welding, wherein in particular the second area is set into rotation and is rotationally friction welded to the first area, or by means of ultrasonic welding and / or that the welding is carried out by means of resistance welding. 38) Method according to one of the preceding claims, further comprising enclosing at least one connecting element or several connecting elements in a housing, in particular overmolding or overcasting the connecting elements with a housing. 39) Charging socket with a front and a rear facing away from the front, with a charging socket receptacle for a charging plug arranged on the front, and a plug extending from the front to the rear, arranged at least partially within the receptacle. Charging cable connector according to one of the preceding claims, wherein the first area starting from the back towards the The charging port recess extends and the second area into the 40) Charging socket according to claim 39, characterized in that the charging socket comprises retaining means for the charging cable connector. 41) System comprising a charging socket according to one of the preceding claims, wherein the charging cable connector is forcefully and / or positively connected to the charging socket and / or the second area of ​​at least one of the connecting elements of the charging cable connector is at least partially arranged in the receptacle of the charging socket and / or the first end face of at least one of the connecting elements projects out of the charging socket along the longitudinal direction of the connecting element.

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