System for connecting two separate busbars to coaxial busbar

Abstract

To allow a system for connecting two separate busbars to a coaxial busbar to optimize electrical connections in electromobility and energy storage systems.SOLUTION: Housing assemblies 2, 3 incorporate dedicated receptacles 10, 7a, 7b for coaxial busbar 4 and separate busbars 6a, 6b, supported by intermediate busbars 5a, 5b, which are conductively connectable, particularly by tight coupling. The connection assembly facilitates efficient and safe assembly and offers flexibility for a variety of applications. The present invention addresses the challenges of electromobility and energy distribution by providing a robust and adaptable solution for integration into compact, power-intensive systems, making it an attractive choice for advanced applications.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a system for connecting busbars. [Background technology]

[0002] Busbars are used in the field of electromobility to carry relatively high currents for charging batteries or for powering electric vehicles. Various systems are used to connect the busbars.

[0003] Since the installation space on electric vehicles is often very limited, the system for connecting the busbars needs to be as compact as possible while at the same time being able to carry high currents with low losses and being easy to manage. Summary of the Invention [Problem to be solved by the invention]

[0004] It is therefore an object of the present invention to create such a system. [Means for solving the problem]

[0005] According to the present invention, the above object is to provide a system for connecting two separate bus bars to a coaxial bus bar comprising at least two bus bars arranged coaxially with respect to one another, the system comprising: a housing assembly including receptacles for the coaxial bus bars, the receptacles extending in an insertion direction, the housing assembly including a first receptacle for one of the two separate bus bars and a second receptacle for the other of the two separate bus bars; and a second receptacle for connecting the receptacle for the coaxial bus bars to the first receptacle. The present invention is satisfied by a system comprising: a first intermediate busbar for connecting a receptacle for the coaxial busbar to a second receptacle, the first intermediate busbar being configured to be conductively connectable to one of the coaxial busbars; and a second intermediate busbar for connecting a receptacle for the coaxial busbar to a second receptacle, the second intermediate busbar being configured to be conductively connectable to the other of the coaxial busbars, the first intermediate busbar and the second intermediate busbar being capable of being positioned spaced apart from each other in the insertion direction in the receptacle.

[0006] The insertion direction is the direction in which the coaxial busbars can be inserted into the housing assembly, which can accommodate the longitudinal extension of the coaxial busbars and allow for accurate positioning within the housing assembly.

[0007] A high degree of reliability and safety is achieved by implementing optimizations in the mechanical configuration and electrical performance of the system according to the present invention, including not only mechanical integrity and electrical conductivity, but also aspects such as touch protection and thermal management capabilities required for long-term safe operation under a variety of operating conditions.

[0008] The above solution can be improved by the following independent, individually advantageous and freely combinable further developments:

[0009] In a preferred embodiment of the system according to the invention, the current-carrying connection between the first intermediate busbar and one of the coaxial busbars and / or the current-carrying connection between the second intermediate busbar and the other of the coaxial busbars is configured as a cohesive bond connection.

[0010] A further preferred embodiment of the system according to the invention comprises a first touch-protective clamping element operable from outside the housing assembly and protruding through the first intermediate busbar into the first receptacle, and a second touch-protective clamping element operable from outside the housing assembly and protruding through the second intermediate busbar into the second receptacle.

[0011] In particular, according to a further particularly preferred embodiment of the invention it is provided that at least one of the tightening elements is configured as a touch-protection screw.

[0012] In a particularly advantageous further development of the system according to the invention, it is provided that the system comprises at least one threaded sleeve which is fastened to one of the two separate busbars, in particular inserted into an opening in one of the two separate busbars and screwed onto the touch protection screw.

[0013] The threaded sleeve is preferably made from steel in order to withstand greater mechanical loads.

[0014] In particular, a wall of the housing assembly can be disposed between the first and second receptacles, which can, for example, prevent creepage currents and improve electrical insulation between the two bus bars.

[0015] It may also be provided that the first screw terminates in a first receptacle and the second screw terminates in a second receptacle.

[0016] Preferably, the intermediate bus bars can each be made of copper, although aluminum or another material with a relatively low electrical resistance is also possible.

[0017] The touch protection screw may be configured such that the screw head and / or opposing screw ends are overmolded with plastic, and the screw shaft formed from steel has a large diameter shoulder located on the surface of the middle bus bar facing away from each of the two separate bus bars.

[0018] The threaded sleeve is fitted into an opening in each of the two separate busbars and can abut, by means of a radially outwardly projecting collar, a surface of each of the two separate busbars facing away from the respective intermediate busbar.

[0019] The openings in each of the two separate busbars may be configured as round holes that are closed all around or open on one side, or as elongated holes that are closed all around or open on one side.

[0020] In a further preferred embodiment of the system according to the invention, the first receptacle and the second receptacle extend in the housing assembly in a direction extending transversely to the insertion direction.

[0021] In a further preferred embodiment of the system according to the invention, it is provided that the first intermediate busbar and the second intermediate busbar each comprise a first connection portion arranged in a receptacle for the coaxial busbar and a second connection portion arranged in the first receptacle for one of the two separate busbars or in the second receptacle for the other of the two separate busbars.

[0022] In yet another particularly advantageous embodiment of the system according to the invention, it is provided that the first connecting part is configured at least partially in the form of a sleeve or hollow cylinder, or at least partially in the form of a plane.

[0023] According to yet another preferred embodiment of the invention, it is provided that the main direction of extension of the first connecting part is changed compared to the main direction of extension of the first connecting part, this change in direction being formed in particular by angular deformation between the connecting parts.

[0024] In a further advantageous embodiment of the system according to the invention, it is provided that the second connection part is configured as a clamping tab, which comprises an opening through which a corresponding clamping element is guided.

[0025] The openings in the fastening tabs can be configured as round holes that are closed all around or open on one side, or as elongated holes that are closed all around or open on one side.

[0026] In a system according to the invention according to a further preferred embodiment of the invention, the opening of the fastening tab is insulated from each of the two separate bus bars.

[0027] For example, the first and second screws may each be guided through a plastic sleeve that is inserted into openings in the first and second intermediate busbars and extends from these openings to the associated first and second threaded sleeves.

[0028] The intermediate busbar and the busbar connected to it of the two separate busbars may be in direct contact with each other, or the intermediate busbar and the connected busbar of the two separate busbars may be spaced apart from each other, with the electrical connection between them being established solely by a screw connection.

[0029] In another particularly preferred embodiment of the system according to the invention it is provided that the first intermediate busbar and the second intermediate busbar can each be configured as an L-shaped element.

[0030] In a particularly advantageous development of the system according to the invention, it is provided that the housing assembly comprises a first housing half in which receptacles for the coaxial busbars are arranged and a second housing half which can be plugged into the first housing half and in which both the first receptacle and the second receptacle are arranged.

[0031] In particular, the first housing half and the second housing half may each be made from plastic, in particular glass-fiber reinforced plastic.

[0032] According to a particularly advantageous embodiment of the system according to the invention, the intermediate busbar is at least partially arranged in the second half of the housing.

[0033] Preferably, each intermediate busbar can be configured as a multi-layer metal sheet that ensures flexibility perpendicular to the plane of the sheet, improving adaptability through high flexibility and optimizing current conduction by reducing resistive losses and increasing electrical efficiency.

[0034] A further advantageous embodiment of the invention arises in that the clamping element is attached to the first housing half.

[0035] In particular, the screw heads of the screws may each include external plastic threads that thread into the internal threads of the second housing half, and the screw shanks of the screws may each include external threads that thread into the internal threads of a threaded sleeve, which is preferably formed from steel.

[0036] In particular, in order to enable the screws to be fixed, the clamping openings in the second housing half, into which the respective screws are inserted, can be at least partially covered by a screw holder attached in a form-fitting manner to the second housing half.

[0037] Further, according to the present invention, there is provided a connection assembly comprising the above-described system, a coaxial busbar and two separate busbars, one of the two separate busbars being connected to the first intermediate busbar at a first receptacle by a first clamping element, and the other of the two separate busbars being connected to the second intermediate busbar at a second receptacle by a second clamping element.

[0038] The connection assembly according to the invention offers several advantages that make it particularly attractive for use in modern electromobility and energy system applications. By combining a coaxial busbar with an intermediate busbar, the assembly improves electrical conductivity and minimizes losses, while the robust construction and touch-protection components ensure high mechanical stability and safety. The simple assembly allows for fast and flexible installation that can be easily adapted to various requirements.

[0039] At least two of the bus bars of the coaxial bus bar may be formed from aluminum or an alloy containing aluminum.

[0040] In particular, at least two bus bars of a coaxial bus bar may be separated from each other by an intermediate insulator and surrounded by an outer insulator.

[0041] In a preferred further development, it may be provided that the coaxial busbar comprises exactly two busbars, which are cylindrically configured, the first busbar forming a cylindrical core and the second busbar forming a hollow cylindrical shell within the coaxial busbar.

[0042] Each of the intermediate bus bars may include a hollow cylindrical portion surrounding a respective one of the coaxial bus bars and a planar portion protruding from the respective bus bar and including an opening through which the screw passes.

[0043] In an alternative preferred development, it is provided that the coaxial busbar comprises exactly two busbars and a flattened rectangular cross-sectional profile, the first busbar forming a flattened rectangular core and the second busbar forming a flattened rectangular hollow shell within the coaxial busbar.

[0044] Each intermediate busbar may be configured as an L-shaped angled element with one leg positioned across the long underside of a respective one of the coaxial busbars and with the leg angled away from the other leg including an opening for receiving a screw.

[0045] The two separate busbars may be arranged adjacent and parallel to one another, in particular offset in a direction extending parallel to the longitudinal extension of the coaxial busbar.

[0046] The two intermediate bus bars can be arranged adjacent to and parallel to one another, in particular arranged adjacent to and parallel to one another, offset in a direction extending parallel to the longitudinal extension of the coaxial bus bars.

[0047] In an advantageous embodiment of the connection assembly according to the invention, it is provided that the fastening tabs of the intermediate busbar each abut directly against a corresponding one of the two separate busbars.

[0048] According to a preferred embodiment of the present invention, in the receptacle for the coaxial busbars, each intermediate busbar is connected to a corresponding busbar of the coaxial busbars by a cohesive bond.

[0049] The tightly bonded connection between the first (second) intermediate busbar and one (the other) of the two busbars of the coaxial busbar can be established by welding, in particular by torsional ultrasonic welding, friction welding, electron beam welding, nanofoil welding or roll seam welding, or by soldering, in particular by induction brazing.

[0050] The receptacle for the coaxial busbar may include an inner contour perpendicular to the insertion direction that corresponds to the outer contour of the coaxial busbar together with an intermediate busbar attached to the coaxial busbar perpendicular to the longitudinal extension of the coaxial busbar, thereby allowing the coaxial busbar provided with the intermediate busbar to be easily inserted into the receptacle for the coaxial busbar.

[0051] According to a further embodiment of the invention, it is further provided that the first housing half is configured to be pre-assembled with the clamping elements, the coaxial busbars and the intermediate busbars, and the second housing half is configured to be pluggable into the first housing half.

[0052] In a particularly preferred manner, the second housing half is configured to be pre-assembled with two separate bus bars.

[0053] The cooling device may be incorporated into the construction of the connection assembly.

[0054] The above-mentioned embodiments will be described in more detail below by means of embodiments with reference to the drawings, in which the same reference numerals are used for elements that correspond to each other in terms of function and / or structure.

[0055] In accordance with the above, if the technical effect associated with a feature of an embodiment described below is not important for a particular application, that feature may be omitted. Conversely, in accordance with the above considerations, a feature not present in the embodiment described below may be added if the technical effect associated with the added feature is important for a particular application. [Brief explanation of the drawings]

[0056] [Figure 1] 1 is a schematic perspective exploded view of a first embodiment with a coaxial bus bar; FIG. [Figure 2] FIG. 2 is a schematic cross-sectional view of the embodiment of FIG. 1. [Figure 3]FIG. 10 is a schematic perspective exploded view of a second embodiment with coaxial bus bars. [Figure 4] FIG. 4 is a schematic cross-sectional view of the embodiment of FIG. 3. [Figure 5] FIG. 10 is a schematic perspective exploded view of a third embodiment. [Figure 6] FIG. 6 is a schematic cross-sectional view of the embodiment of FIG. 5. [Figure 7] FIG. 10 is a schematic perspective exploded view of a fourth embodiment. [Figure 8] FIG. 8 is a schematic cross-sectional view of the embodiment of FIG. 7. [Figure 9] FIG. 10 is a schematic perspective cross-sectional view of a fifth embodiment. [Figure 10] FIG. 10 is a schematic diagram of an assembly sequence for manufacturing the sixth embodiment. [Figure 11] FIG. 10 is a schematic diagram of an assembly sequence for manufacturing the sixth embodiment. [Figure 12] FIG. 10 is a schematic diagram of an assembly sequence for manufacturing the sixth embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0057] The illustrated system 20 is used to connect a coaxial busbar 4 to two separate busbars 6a, 6b. The coaxial busbar 4 includes two coaxially arranged busbars 4a, 4b, typically made from aluminum or an aluminum alloy, ensuring high electrical conductivity and mechanical stability. The two busbars 4a, 4b are insulated from each other by an intermediate insulator 4c and further surrounded by an outer insulator 4d, improving the electrical safety and insulation integrity of the system.

[0058] The system 20 establishes an electrical connection between the coaxially arranged and insulation-stripped busbars 4a, 4b of the coaxial busbar 4 and two external, separate busbars 6a, 6b. Together with the coaxial busbar 4 and the two separate busbars 6a, 6b, the system 20 forms a connection assembly 1 that can be used as a DC connector in a charging port of an electric vehicle.

[0059] The system 20 comprises housing assemblies 2, 3 that provide receptacles 10 for the coaxial busbars 4. The receptacles 10 extend in an insertion direction E, which in the illustrated embodiment coincides with the longitudinal extension of the coaxial busbars 4. Furthermore, the housing assemblies 2, 3 include a first receptacle 7a for receiving one of the separate busbars 6a and a second receptacle 7b for receiving the other separate busbar 6b, allowing for accurate positioning and connection of the busbars 6a, 6b.

[0060] As can be particularly seen from the exploded views of Figures 1, 3, 5, and 7 and the assembly sequence of Figures 10-12, the housing assembly 2, 3 is comprised of a first housing half 2 including a receptacle 10 for a coaxial busbar 4, and a second housing half 3. The second housing half 3, which is connected to the first housing half 2 by interdigitation, includes both a first receptacle 7a for a separate busbar 6a and a second receptacle 7b for a separate busbar 6b.

[0061] To ensure high strength and durability, the first and second housing halves 2, 3 are formed from a plastic material, preferably a glass fiber reinforced plastic material. A peripheral seal 30 is incorporated between the housing halves 2, 3 to ensure an effective seal after the housing halves 2, 3 are inserted together.

[0062] After the two housing halves 2, 3 are plugged together, the intermediate busbars 5a, 5b are arranged to be connectable to the busbars 4a, 4b of the coaxial busbar 4 in the first housing half 2 and simultaneously protrude into the receptacles 7a, 7b for the separate busbars 6a, 6b in the second housing half 3. The receptacles 7a, 7b for the separate busbars 6a, 6b are configured to be at least partially located in both housing halves 2, 3 after the housing halves 2, 3 are plugged together. In addition, some of the receptacles 7a, 7b may be located in only one of the housing halves 2, 3. This configuration allows for efficient use of space and stable fastening of the separate busbars 6a, 6b, as shown in the cross-sectional views of Figures 2, 4, 6, 8, 9, and 10-12.

[0063] 1, 3, 6 and 8 clearly show that the first receptacle 7a for one separate busbar 6a and the second receptacle 7b for the other separate busbar 6b ​​are assembled in the housing assemblies 2, 3 such that they have an orientation perpendicular to the insertion direction E. This allows for a space-saving arrangement of the receptacles 7a, 7b which are arranged parallel to one another and offset in a direction parallel to the insertion direction E of the coaxial busbars 4, ensuring optimal use of the space within the connection assembly 1.

[0064] As shown in the perspective exploded views according to Figures 1, 3, 5 and 7 and in the cross-sectional views parallel to the insertion direction E according to Figures 6 and 8, the system 20 comprises a first intermediate busbar 5a connected by tight coupling to one of the busbars 4a of the coaxial busbars 4, and a second intermediate busbar 5b similarly connected by tight coupling to the other busbar 4b of the coaxial busbars 4. Each of the two intermediate busbars 5a, 5b is made of copper, which is crucial for good electrical conductivity and mechanical stability.

[0065] The tightly bonded connection of each of the first and second intermediate busbars 5a, 5b, both made of copper, to one of the coaxially arranged busbars 4a, 4b of the coaxial busbar 4 made of aluminum or an aluminum alloy can be achieved by various welding methods including torsional ultrasonic welding, friction welding, electron beam welding, nanofoil welding or roll seam welding, or by soldering such as induction brazing.

[0066] As shown in Figures 2, 4, 6 and 8, cross sections perpendicular and parallel to the insertion direction E, which in this example coincides with the longitudinal extension direction L of the coaxial busbar 4, show that the first intermediate busbar 5a extends from the receptacle 10 for the coaxial busbar 4 to a first receptacle 7a for one of the two separate busbars 6a. Similarly, the second intermediate busbar 5b extends from the receptacle 10 for the coaxial busbar 4 to a second receptacle 7b for the other of the two separate busbars 6b.

[0067] As can be seen particularly clearly from Figures 1, 3, and 5 to 9, two separate busbars 6a, 6b can be arranged adjacent to and parallel to one another, or more precisely, adjacent to and parallel but offset from one another in a direction extending parallel to the insertion direction E. Accordingly, the intermediate busbars 5a, 5b can also be arranged adjacent to and parallel to one another, or more precisely, adjacent to and parallel but offset from one another in a direction extending parallel to the insertion direction E. The first intermediate busbar 5a and the second intermediate busbar 5b are positioned in the insertion direction E within the receptacle 10 at a fixed distance from one another, enabling an orderly and efficient connection configuration.

[0068] To securely fasten the intermediate busbars 5a, 5b to the respective individual busbars 6a, 6b, screws 8a, 8b are used as touch-safe fastening elements operable from outside the housing assemblies 2, 3. For this purpose, a first touch-safe screw 8a, accessible from outside the housing assemblies 2, 3, is inserted through the first intermediate busbar 5a into the corresponding receptacle 7a of one of the busbars 6a. Similarly, a second touch-safe screw 8b is inserted through the second intermediate busbar 5b into the receptacle 7b for the other busbar 6b. This allows for a strong and reliable connection, as particularly shown in the cross-sectional views of Figures 6 and 8.

[0069] The first and second intermediate busbars 5a, 5b are fastened to the separate busbars 6a, 6b by a two-point threaded connection using threaded sleeves 9a, 9b. The first threaded sleeve 9a is provided with an internal thread 24 into which the external thread 25 of the threaded end 23 of the first screw 8a engages, and the second threaded sleeve 9b includes a corresponding internal thread 24 into which the external thread 25 of the threaded end 23 of the second screw 8b engages. As can be seen from the cross-sectional views according to Figures 2, 4, 6, 8 and 9, this form-fit connection ensures a secure and permanent fastening.

[0070] The threaded shafts 22 and threaded sleeves 9a, 9b of the two screws 8a, 8b are made of steel and include enlarged shoulders 19 that abut the surfaces of the intermediate busbars 5a, 5b facing away from their respective individual busbars 6a, 6b. This configuration ensures a reliable mechanical and electrical connection between the intermediate busbars 5a, 5b and the individual busbars 6a, 6b, which is important for the integrity of the system. Touch protection for the screws 8a, 8b is provided by overmolding the screw heads 21 and the opposing threaded ends 23 with plastic material.

[0071] As can be seen from the cross-sectional views shown in Figures 6 and 8, each extending parallel to the insertion direction E, the touch protection screws 8a, 8b are sized and positioned so that the first screw 8a terminates in a first receptacle 7a for one separate busbar 6a and the second screw 8b terminates in a second receptacle 7b for the other separate busbar 6b.

[0072] Threaded sleeves 9a, 9b, made of steel and shown in Figures 1 to 4 and 9 to 12, fit precisely into the openings 16 in the individual busbars 6a, 6b and abut, by means of radially projecting collars 27, against the surface of each busbar 6a, 6b facing away from the respective intermediate busbar 5a, 5b. Tightening of the screws 8a, 8b into the threaded sleeves 9a, 9b therefore ensures a solid mechanical and electrical connection between the intermediate busbars 5a, 5b and the individual busbars 6a, 6b. The variants shown in Figures 5 to 8 show that the individual busbars 6a, 6b can be made integral with the threaded sleeves 9a, 9b, which entails additional advantages in manufacturing and assembly.

[0073] 1-4 and 9-12, the openings 16 in the separate busbars 6a, 6b are configured as circumferentially closed round holes for receiving the first threaded sleeve 9a of the first screw 8a and the second threaded sleeve 9b of the second screw 8b. Alternatively, to allow for assembly flexibility, these openings 16 can be configured as elongated holes, or as round or elongated holes that are open on one side, to facilitate alignment and fastening of the components during assembly.

[0074] 1, 2, 5 and 6 show views of a first and third embodiment of a system 20 according to the invention, characterized in that for a cylindrical coaxial busbar 4, in which the first busbar 4a forms a cylindrical core and the second busbar 4b forms a hollow cylindrical shell within the coaxial busbar 4, the first intermediate busbar 5a and the second intermediate busbar 5b comprise as first connection portions 11 sleeve-like or hollow cylindrical portions which are respectively placed in receptacles 10 for the coaxial busbars 4.

[0075] These first connection portions 11 in the form of sleeve-like or hollow cylindrical portions of the intermediate busbars 5a, 5b are positioned in receptacles 10 for the coaxial busbars 4 so as to at least partially engage around the exposed cylindrical inner busbar 4a and the exposed hollow cylindrical outer busbar 4b of the coaxial busbar 4. This arrangement creates a large contact surface between the intermediate busbars 5a, 5b and the respective busbars 4a, 4b of the coaxial busbar 4 in a tightly bonded connection which can be achieved by a welding or soldering process, thus ensuring a high connection quality.

[0076] In the modifications shown in the second and fourth embodiments of the system 20 of the present invention according to Figures 3, 4, 7 and 8, the coaxial busbars 4 have respective flat rectangular cross-sectional profiles, with the first busbar 4a forming a flat rectangular core and the second busbar 4b forming a flat rectangular hollow shell within the coaxial busbar 4.

[0077] Here, L-shaped angled elements are used as intermediate busbars 5a, 5b. First legs 28a of these L-shaped elements establish a tight-fitting connection with the corresponding flat rectangular busbars 4a, 4b of the coaxial busbar 4. For this purpose, the first legs 28a abut over their entire surfaces against the long undersides of the respective busbars 4a, 4b of the coaxial busbar 4. A second leg 28b protruding at a right angle from the first leg 28a forms a flat portion as the second connecting part 12, which includes openings 14 for the corresponding screws 8a, 8b, thereby facilitating assembly of the screw connection and providing a robust mechanical and electrical connection.

[0078] The fifth embodiment shown in Figure 9 shows intermediate busbars 5a, 5b of a system 20 according to the invention, which combines the form factors of the previous embodiments. These intermediate busbars 5a, 5b have an arc-shaped connection 29a between two parallel-extending legs 29b, 29c. This structure closely fits the oppositely arranged long and lateral sides of the flat busbars 4a, 4b of the coaxial busbar 4, creating an optimized contact surface for an effective connection. This configuration provides a large contact surface and ensures a strong and reliable tight-coupled connection.

[0079] In the embodiment according to FIGS. 1 to 12, screws 8a, 8b are each fastened to the first housing half 2. Each screw 8a, 8b has a touch-protective head 21, which is protected by a plastic overmold and includes a plastic external thread 31. This external thread 31 engages with a corresponding internal thread 32 in a fastening opening 17 of the first housing half 2. The fastening opening 17 of the first housing half 2, into which the screws 8a, 8b are inserted, is at least partially covered by a screw holder 18a, 18b, which is form-fittingly connected to this housing half 2. This arrangement secures the screws 8a, 8b against unintentional loosening and thus ensures a permanent and reliable connection of the housing halves 2, 3.

[0080] As shown in Figures 1, 5 and 7, the openings 14 for the screw connections in the fastening tabs 13 of the intermediate busbars 5a, 5b are each configured as a round hole that is closed all around. In contrast, the openings 14 in Figure 3 are configured as elongated holes that are open on one side. These various configuration options for the openings 14, whether round or elongated, closed all around or open on one side, allow for flexible adaptation to given installation requirements and environments.

[0081] The optimized mechanical design of the presented system 20 ensures reliability and safety, including robust mechanical stability, excellent electrical conductivity, effective touch protection, and excellent temperature regulation, all of which are essential for long-term, safe use under a wide range of conditions.

[0082] The cross-sectional views according to Figures 6 and 8 taken along a section parallel to the insertion direction E show the partition wall 26, which is arranged in the housing assemblies 2, 3 between the receptacles 7a, 7b for the separate busbars 6a, 6b, providing spatial separation and structural support.

[0083] As shown in Figures 1, 2, and 5 to 9, the first screw 8a and the second screw 8b are guided through plastic sleeves 15a, 15b, respectively, inserted into the openings 14 of the corresponding intermediate busbars 5a, 5b. These plastic sleeves 15a, 15b extend from the openings 14 to the threaded sleeves 9a, 9b, thereby providing additional touch protection. This design minimizes the risk of direct contact with live parts, contributing to the safety of the connection assembly 1.

[0084] According to the embodiments shown in Figures 3, 4 and 10 to 12, the use of plastic sleeves 15a, 15b may alternatively be omitted. In such a configuration, intermediate busbars 5a, 5b are directly connected to corresponding busbars 6a, 6b of two separate busbars 6a, 6b. This direct connection simplifies the design and increases reliability, even if it does not guarantee the highest level of touch protection.

[0085] Depending on the configuration, with or without incorporating plastic sleeves 15a, 15b, the intermediate busbars 5a, 5b and the associated separate busbars 6a, 6b can be spatially separated from one another, as shown in the embodiments according to Figures 1, 2 and 5 to 9. In such a configuration, the screw connection not only establishes a fixed mechanical connection, but also a direct electrical connection between the intermediate busbars 5a, 5b and the separate busbars 6a, 6b.

[0086] In the fifth embodiment of FIG. 9, the intermediate busbars 5a, 5b are configured as multilayer metal sheets, which provide the intermediate busbars 5a, 5b with significant flexibility. This flexibility is ensured particularly along the insertion direction, i.e., parallel to the longitudinal axis of the screw. The illustration in FIG. 9, highlighted by the double arrow near the arc-shaped connection 29a, shows this flexibility of the intermediate busbars 5a, 5b. In addition, limited mobility of the intermediate busbars 5a, 5b parallel to the insertion direction E is also possible. As a result, this flexibility of the intermediate busbars 5a, 5b improves the adaptability of the connection assembly 1 to various assembly situations.

[0087] Although not explicitly shown in this figure, cooling devices, particularly in the form of integral cooling channels, may be incorporated into the structure of the housing assemblies 2, 3 to ensure effective heat dissipation from all busbars 4a, 4b, 5a, 5b, 6a, 6b and thereby optimal operating temperatures during the charging process.

[0088] 10-12 show an assembly sequence for manufacturing a connection assembly 1 according to the present invention.

[0089] 10, the first housing half 2 and the second housing half 3 are initially provided in a pre-assembled state, respectively. In this pre-assembled state, the first housing half 2 comprises fastening elements 8a, 8b in the form of touch-protection screws already inserted in the fastening openings 17, the coaxial busbar 4 is inserted in the receptacle 10 in the insertion direction E, and the intermediate busbars 5a, 5b are connected by a tight joint to the exposed busbars 4a, 4b of the coaxial busbar 4. Furthermore, in this pre-assembled state, the second housing half 3 comprises separate busbars 6a, 6b inserted in the receptacles 7a, 7b.

[0090] In Figure 10, the screws 8a, 8b attached to the first housing half 2 are not yet in their fully inserted pre-position. The two pre-assembled housing halves 2, 3 are therefore plugged into one another to form the housing assembly 2, 3, as represented by the thick arrows pointing vertically downwards in Figure 10, with this plugging direction extending perpendicular to the insertion direction E.

[0091] Figure 11 shows the end of the insertion process, where the openings 14 of the fastening tabs 13 of the intermediate busbars 5a, 5b are aligned with the openings 33 of the threaded sleeves 9a, 9b, which are fitted into the openings 16 of the separate busbars 6a, 6b in a direction perpendicular to the insertion direction E and the insertion direction according to Figure 10. In this intermediate assembly state according to Figure 11, with the openings 14, 16, 33 aligned, the insertion and tightening of the two screws 8a, 8b can begin. This start of insertion is represented in Figure 11 by the two thick arrows on the screws 8a, 8b in the fastening openings 17 of the first housing half 2.

[0092] 12 shows the completion of the insertion and screw tightening process of the screws 8a, 8b, which also completes the assembly process by obtaining a connection assembly 1 according to the invention. For both screws 8a, 8b, each threaded end 23 passes through the opening 14 in the clamping tab 13 and is then screwed by the external threads 25 into the internal threads 24 of the threaded sleeves 9a, 9b.

[0093] After the insertion and tightening process of the two screws 8a, 8b is complete, the enlarged shoulder 19 of the screw shaft 22 contacts the surface of the fastening tab 13 facing away from each individual busbar 6a, 6b, as shown in Figure 12. The threaded sleeves 9a, 9b also include enlarged collars 27 that abut the surface of each individual busbar 6a, 6b facing away from their respective fastening tabs 13, so that tightening the screws 8a, 8b creates a rigid force-fit connection between the intermediate busbar 5a, 5b and the individual busbars 6a, 6b. The intermediate busbars 5a, 5b are further tightened into the first housing half 2, and the individual busbars 6a, 6b are further tightened into the second housing half 3, so that tightening the screws 8a, 8b subsequently rigidly connects the two housing halves 2, 3 to each other simultaneously.

[0094] This results in a very simple assembly. It should be emphasized that in the embodiment according to Figures 10 to 12, no separate plastic sleeves 15a, 15b are used, as in the embodiments according to Figures 1, 2 and 5 to 9. Instead, by simply inserting and tightening the two screws 8a, 8b, the mutually facing surfaces of the intermediate busbars 5a, 5b and the individual busbars 6a, 6b come into direct pressure contact, simply creating a reliable mechanical and electrical connection between the intermediate busbars 5a, 5b and the individual busbars 6a, 6b.

[0095] The presented connection assembly 1 features many advantages that make it particularly suitable for use in advanced electromobility and energy systems. The innovative combination of the coaxial busbar 4 and the intermediate busbars 5a, 5b not only optimizes electrical conductivity but also minimizes energy losses. Thanks to its robust design and the implementation of touch-protection components, the assembly offers excellent mechanical stability and a high level of safety. In addition, the assembly's easy design allows for fast and flexible installation and can be easily adapted to various operating conditions and requirements. [Explanation of symbols]

[0096] 1 Connection Assembly 2 First housing half (housing assembly) 3 Second housing half (housing assembly) 4 Coaxial busbars 4a, 4b busbars (coaxial busbars) 4c, 4d Intermediate insulator / Outer insulator (coaxial busbar) 5a, 5b Intermediate busbars 6a, 6b Separate busbars 7a, 7b Receptacles (for separate busbars) 8a, 8b Clamping elements (touch protection screws) 9a, 9b Threaded sleeve 10 Receptacle (for coaxial busbar) 11 First connection 12 Second connection 13 Fastening tab 14 Opening (fastening tab) 15a, 15b Plastic sleeve 16 Openings (separate busbars) 17 Fastening opening (first housing half) 18a, 18b Screw holder 19 Shoulder (screw) 20 Systems 21 Screw head 22 Screw shaft 23 Thread end 24 Female thread (threaded sleeve) 25 Male thread (thread end) 26 Partition wall (housing assembly) 27 Collar (Threaded Sleeve) 28a, 28b Legs (intermediate busbar) 29a Arc-shaped joint 29b, 29c Legs (intermediate busbars) 30 stickers 31 Plastic male screw (screw head) 32 Female thread (fastening opening) 33 Opening (threaded sleeve) E Insertion direction

Claims

1. A system (20) for connecting two separate busbars (6a, 6b) to a coaxial busbar (4) comprising at least two busbars (4a, 4b) arranged coaxially with respect to one another, comprising: a housing assembly (2, 3) including a receptacle (10) for the coaxial busbar (4), the receptacle (10) extending in an insertion direction (E), the housing assembly (2, 3) comprising: a first receptacle (7a) for one of the two separate busbars (6a); and a housing assembly (2, 3) including a second receptacle (7b) for the other of the two separate bus bars (6b); a first intermediate busbar (5a) for connecting the receptacle (10) for the coaxial busbar (4) to the first receptacle (7a), the first intermediate busbar (5a) being configured to be conductively connectable to one busbar (4a) of the coaxial busbar (4); a second intermediate busbar (5b) for connecting the receptacle (10) for the coaxial busbar (4) to the second receptacle (7b), the second intermediate busbar (5b) being configured to be conductively connectable to the other busbar (4b) of the coaxial busbar (4); wherein the first intermediate bus bar (5a) and the second intermediate bus bar (5b) can be arranged spaced apart from each other in the insertion direction (E) in the receptacle (10). System (20).

2. 2. The system (20) of claim 1, wherein the current-carrying connection between the first intermediate busbar (5a) and the one busbar (4a) of the coaxial busbars (4) and / or the current-carrying connection between the second intermediate busbar (5b) and the other busbar (4b) of the coaxial busbars (4) is configured as a tight-coupled connection.

3. a first touch-protective clamping element (8a) operable from outside the housing assembly (2, 3) and projecting through the first intermediate busbar (5a) into the first receptacle (7a); a second touch-safe clamping element (8b) operable from outside the housing assembly (2, 3) and projecting through the second intermediate busbar (5b) into the second receptacle (7b); The system (20) of claim 1 or 2, comprising:

4. 4. The system (20) according to claim 3, wherein at least one of the tightening elements (8a, 8b) is configured as a touch-protection screw.

5. 5. The system (20) according to claim 4, comprising at least one threaded sleeve (9a, 9b) which is fastened to one of the two separate busbars (6a, 6b), in particular inserted into an opening (16) of one of the two separate busbars (6a, 6b) and screwed onto a touch protection screw (8a, 8b).

6. 6. The system (20) according to any one of claims 1 to 5, wherein the first receptacle (7a) and the second receptacle (7b) extend in the housing assembly (2, 3) in a direction extending transversely to the insertion direction (E).

7. 7. The system (20) according to any one of claims 1 to 6, wherein the first intermediate busbar (5a) and the second intermediate busbar (5b) each include a first connection (11) arranged in the receptacle (10) for the coaxial busbar (4) and a second connection (12) arranged in the first receptacle (7a) for one of the two separate busbars (6a) or the second receptacle (7b) for the other of the two separate busbars (6b).

8. 8. The system (20) according to claim 7, wherein the first connection part (11) is configured at least partially in the shape of a sleeve or hollow cylinder, or at least partially in the shape of a plane.

9. 9. The system (20) according to claim 7 or 8, wherein the main extension direction of the first connecting portion (12) is changed compared to the main extension direction of the first connecting portion (11), said change in direction being formed in particular by an angular deformation between the connecting portions (11, 12).

10. 10. The system (20) according to any one of claims 7 to 9, wherein the second connection (12) is configured as a fastening tab (13), the fastening tab (13) including an opening (14) through which a corresponding fastening element (8a, 8b) is guided.

11. 11. The system (20) of claim 10, wherein the opening (14) of the fastening tab (13) is insulated from a corresponding one of the two separate bus bars (6a, 6b).

12. 12. The system (20) of any one of claims 1 to 11, wherein the first intermediate busbar (5a) and the second intermediate busbar (5b) are each configured as an L-shaped element.

13. 13. The system (20) according to any one of claims 1 to 12, wherein the housing assembly (2, 3) comprises a first housing half (2) in which the receptacle (10) for the coaxial busbar (4) is arranged, and a second housing half (3) that can be plugged into the first housing half (2) and in which both the first receptacle (7a) and the second receptacle (7b) are arranged.

14. 14. The system (20) of claim 13, wherein the intermediate busbar (5a, 5b) is at least partially disposed in the second housing half (3).

15. A system (20) according to claim 13 or 14 to the extent that it relates to claim 3 or any one of claims 4, 6, 7, 12, 13 dependent on claim 3, wherein the clamping elements (8a, 8b) are attached to the first housing half (2).

16. A connection assembly (1), comprising: A system (20) according to any one of claims 1 to 15; A coaxial busbar (4) and two separate busbars (6a, 6b) Equipped with A connection assembly (1), wherein one of the two separate busbars (6a) is connected to the first intermediate busbar (5a) at the first receptacle (7a) by a first clamping element (8a), and the other of the two separate busbars (6b) is connected to the second intermediate busbar (5b) at the second receptacle (7b) by a second clamping element (8b).

17. 17. A connection assembly (1) according to claim 16 to the extent relevant to claim 10 or 11, wherein the fastening tabs (13) of the intermediate busbars (5a, 5b) each directly abut a corresponding one of the two separate busbars (6a, 6b).

18. 18. The connection assembly (1) according to claim 16 or 17, wherein in the receptacle (10) for the coaxial busbar (4), the intermediate busbars (5a, 5b) are each connected to a corresponding busbar (4a, 4b) of the coaxial busbar (4) by means of a tight coupling.

19. 19. A connection assembly (1) according to any one of claims 16 to 18 to the extent that it relates to any one of claims 13 to 15, wherein the first housing half (2) is configured to be pre-assembled with the clamping elements (8a, 8b), the coaxial busbars (4) and the intermediate busbars (5a, 5b), and the second housing half (3) is configured to be pluggable into the first housing half (2).

20. A connection assembly (1) according to any one of claims 16 to 19 to the extent that it relates to any one of claims 13 to 15, wherein the second housing half (3) is configured to be pre-assembled with the two separate busbars (6a, 6b).

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