Assembly of a charging system for charging an electric vehicle

Abstract

The invention relates to an assembly of a charging system for charging an electric vehicle (4), comprising a plug connector part (3) which has an electric plug contact (31A, 31B) for transmitting a charging current, at least one electric load line (21A, 21B) which is electrically connected to the at least one plug contact (31A, 31B) for transmitting the charging current, and at least one coolant line (23A, 23B) in which the at least one electric load line (21A, 21B) is guided and in which a coolant can flow around the at least one electric load line (21A, 21B). The plug connector part (3) has a cooling unit (33) which has at least one connection element (34A, 34B) to which the at least one coolant line (23A, 23B), together with the at least one load line (21A, 21B), is connected. The at least one connection element (34A, 34B) has at least one feed-through channel (341) and a coolant channel (342), wherein the at least one load line (21A, 21B) extends through the feed-through channel (341), and coolant can flow through the coolant channel (342).

Description

[0001] Assembly of a charging system for charging an electric vehicle

[0002] The invention relates to an assembly of a charging system for charging an electric vehicle according to the preamble of claim 1 and a charging system for charging an electric vehicle.

[0003] Such an assembly comprises a connector part having a plug-in section for plugging into a mating connector part and at least one plug contact arranged on the plug-in section for transmitting a charging current. At least one electrical load line is electrically connected to the at least one plug contact for transmitting the charging current. The at least one electrical load line is routed in at least one coolant line, and a coolant can flow around it in the coolant line.

[0004] Such a connector part can be designed as a charging plug or charging socket and can be arranged on a charging cable at a charging station or on an electric vehicle. A charging plug arranged on a charging cable can be connected to a charging socket to establish an electrical connection between a charging station and the electric vehicle and to electrically charge the electric vehicle.

[0005] In the field of electromobility, it is desirable to charge electric vehicles quickly and efficiently to reduce charging times and the associated downtime. To enable rapid charging of an electric vehicle during a fast charging process, high charging powers are used, combined with large charging currents, for example, with a current of 700 A or even higher. Currents of up to 3000 A are even conceivable for charging commercial vehicles.

[0006] When high charging currents are transmitted, the busbar elements and other components of the connector section heat up. For example, regulations stipulate that heating of a connector section may not exceed 50 K. Therefore, when high charging currents are used, care must be taken to prevent excessive heating of the connector section.

[0007] The arrangement and dimensioning of electrical busbar elements on connector parts for charging an electric vehicle is usually prescribed by standards. Contact geometries on such connector parts cannot therefore be easily scaled to potentially achieve a greater current-carrying capacity on the busbar elements. One challenge, therefore, is to enable the greatest possible power transmission with existing contact geometries.

[0008] In principle, it is possible to increase the current-carrying capacity of, for example, a charging cable and a charging plug connected to the charging cable by increasing the cross-section of the current-carrying load lines. However, because a charging cable must be handled manually by a user, there are limits to increasing the cross-section of the load lines and the associated increase in weight of the charging cable.

[0009] One way to improve the current-carrying capacity of the charging cable, charging plug, and charging socket is to provide active cooling for the current-carrying components, especially the charging cable and the charging plug connected to the charging cable. If water or a water mixture (e.g., using antifreeze components) is used as the cooling medium, care must be taken to ensure that the cooling medium does not come into contact with current-carrying components, or, if such contact does occur (as intended), that the operational readiness and reliability of the charging system are not compromised.

[0010] In a charging connector known from EP 3 103 173 B1, a cooling unit through which a coolant can flow is arranged between busbar components. A flow channel is defined in a housing of the cooling unit, which is designed to guide the coolant flow tangentially along the busbar components.

[0011] In a connector component known from DE 10 2016 107 409 A1, a coolant flow flows through heat sinks. The heat sinks are connected to associated busbar elements via heat pipes, which absorb heat from the busbar elements via the heat pipes.

[0012] From CH 715 611 B1 a connection element for the electrical connection of a fluid-coolable individual line is known.

[0013] DE 10 2021 114 495 A1 describes a charging cable that provides active cooling by flowing a cooling medium around free areas of a stranded wire forming a load line within a coolant hose. The object of the present invention is to provide a charging system assembly that enables active cooling of current-carrying components while efficiently absorbing heat at the current-carrying components.

[0014] This object is achieved by an article having the features of claim 1.

[0015] Accordingly, the connector part has a cooling unit which has at least one connection element to which the at least one coolant line is connected together with the at least one load line, wherein the at least one connection element has a feedthrough channel and a coolant channel, wherein the at least one load line extends through the feedthrough channel and coolant can flow through the coolant channel.

[0016] An assembly of a charging system for charging an electric vehicle comprises a connector part, at least one electrical load line, and at least one coolant line. The at least one electrical load line and the at least one coolant line are connected to the connector part, so that a charging current can be conducted to an associated plug contact of the connector part via the electrical load line, while cooling is provided via the coolant line both in the area of ​​the load line and in the area of ​​the plug contact.

[0017] The connector part can be designed, for example, as a charging plug on a charging cable. In this case, the at least one electrical load line and the at least one coolant line are part of the charging cable and connect the connector part in the form of the charging plug, for example, to a stationary charging station. The connector part in the form of a charging plug can be connected in a plug-in manner to a mating connector part in the form of a charging socket on the side of an electric vehicle, thus establishing an electrical connection between the charging station and the electric vehicle and introducing a charging current into the vehicle batteries of the electric vehicle.

[0018] In another embodiment, the connector part can be a charging socket, for example, on the side of an electric vehicle. In this case, the at least one electrical load line and the at least one coolant line extend, for example, within the vehicle.

[0019] The at least one coolant line is configured such that the at least one coolant line carries the at least one electrical load line within its interior, such that coolant can flow around the at least one electrical load line within the coolant line. For example, the coolant line is in the form of a hose that defines an inner lumen within which the associated load line is accommodated. During operation, a charging current is conducted via the load line, and coolant is also conducted through the coolant line, so that the coolant flows around the load line and thus provides cooling directly at the load line.

[0020] The load line can, for example, be in the form of an electrical strand that is routed within the coolant line. For example, the load line has no electrical insulation, so that the coolant inside the coolant line comes into direct (electrical) contact with the load line. In another embodiment, the load line can be electrically insulated using an insulating sheath, so that coolant can flow around the load line inside the coolant line but does not come into contact with an electrically conductive core of the load line.

[0021] For example, the load line may be extended centrally within the coolant line, wherein spacers may hold the load line in a predetermined position within the coolant line.

[0022] A water-based coolant, such as a mixture of water and antifreeze components, can be used as the coolant. In other embodiments, an oil-based coolant can also be used.

[0023] Because the at least one electrical load line is accommodated in the at least one coolant line and is surrounded by coolant within the coolant line during operation, active cooling can be provided directly at the load line, for example along the length of a charging cable.

[0024] In order to provide cooling to the load line accommodated in the coolant line, the inner diameter of the coolant line, which can be formed, for example, by a coolant-carrying hose, must be selected such that coolant can flow around the load line accommodated in the coolant line within the coolant line. Because the load line must not fall below a minimum cross-section to ensure a sufficiently large current-carrying capacity (otherwise the power loss in the conductor would increase excessively), the inner diameter of the coolant line must be selected to be larger than the diameter of the load line. However, it cannot be selected to be arbitrarily large because increasing the diameter of the coolant line (when the connector part is designed as a charging plug on a charging cable) leads to an increase in the diameter of the entire charging cable and thus may impair the handling of the charging cable.For this reason, the diameter of the coolant line is advantageously selected to be only slightly larger than the load line, namely just large enough so that the load line can be surrounded by coolant within the coolant line in such a way that heat can be efficiently absorbed at the load line and transported away from the load line.

[0025] However, an only slightly larger inner diameter of the coolant line compared to the outer diameter of the load line accommodated in the coolant line may cause difficulties when connecting the coolant line to the cooling unit, because a connecting element in the form of a grommet element onto which the coolant line is plugged may further reduce the space between the coolant line and the load line.

[0026] For this reason, the cooling unit has at least one connection element to which the at least one coolant line is connected together with the at least one load line and which has a feed-through channel for the load line to pass through and also a coolant channel for guiding coolant. The connection element can, for example, take the form of a grommet element onto which the coolant line is plugged. Because the connection element has a separate coolant channel for guiding the coolant, a coolant flow between the cooling unit and the coolant line is ensured, so that coolant can, for example, be introduced into the coolant line in the return line from the cooling unit or, conversely, coolant can flow from the coolant line into the cooling unit in the supply line.

[0027] Because the load line is routed through the connecting element in the feedthrough channel and thus extends from the coolant line into the cooling unit, the path of the load line at the connecting element is predetermined by the feedthrough channel. The load line can be compressed in the feedthrough channel, so that the load line, formed, for example, by a stranded conductor, is accommodated in a spatially compact manner at the connecting element.

[0028] By compressing the load line, which may be configured as a stranded conductor in this way, pressure loss at the connecting element can be kept to a minimum due to a reduced flow cross-section for the coolant in the area of ​​the connecting element. In one embodiment, the connecting element has a body within which the feed-through channel and the coolant channel are formed. The body preferably forms a grommet onto which the coolant line with the load line guided therein is plugged, so that in the assembled position, the tubular coolant line is slipped over the connecting element and the load line is guided through the feed-through channel within the body. In the assembled position, the connecting element thus engages with the body in the coolant line.A flow path between a free lumen of the coolant line and the cooling unit remains free via the coolant channel, so that a flow connection between the cooling unit and the coolant line is reliably established via the coolant channel and provides a sufficient flow cross-section for guiding the coolant.

[0029] In one embodiment, the cooling unit forms a flow space through which coolant can flow, wherein the flow channel of the at least one connection element is in flow connection with the flow space. In addition to cooling on the at least one load line via the at least one coolant line, active cooling is also provided on the connector part. For this purpose, the cooling unit forms a flow space through which coolant can flow. One or more coolant lines are connected to the cooling unit for introducing coolant into the flow space or for discharging coolant from the flow space.

[0030] In one embodiment, the at least one electrical load line extends through the feedthrough channel of the at least one connection element into the flow chamber for electrical connection to the at least one plug contact. Each load line extends in an associated coolant line. The coolant line is connected to the cooling unit via the associated connection element such that a flow connection exists between the coolant line and an associated flow chamber inside the cooling unit. Coolant can thus be conducted between the cooling unit and the coolant line.The load line extending in the coolant line extends from the coolant line through the feedthrough channel of the connection element into the cooling unit, so that the load line is surrounded by coolant within the flow space in the area of ​​an electrical transition to an associated plug contact and thus cooling is also provided within the connector part in the area of ​​the plug contact.

[0031] In one embodiment, at least one further coolant line is connected to the cooling unit to establish a coolant flow through the flow chamber. For example, each flow chamber of the cooling unit can be assigned a (first) coolant line, within which an associated load line extends and is contacted within the flow chamber with an associated plug contact, for example via a busbar element carrying the plug contact. In addition, each flow chamber is assigned a (second) coolant line. One of the coolant lines serves as the supply line and the other of the coolant lines as the return line for the coolant. A closed coolant flow can thus be provided via the pair of coolant lines, within which coolant is supplied to the cooling unit via the supply line, flows through the flow chamber of the cooling unit, and is discharged again via the return line.During operation, a coolant flow is created, which absorbs heat from the load line and also in the area of ​​the associated plug contact on the connector part.

[0032] The (first) coolant line, within which the associated load line is routed, can serve as a return line, for example. The other (second) coolant line, on the other hand, can serve as a supply line for the coolant.

[0033] In one embodiment, the at least one plug contact is arranged on the cooling unit. The at least one plug contact is preferably mechanically fixed to the cooling unit, so that the cooling unit, together with the at least one plug contact arranged thereon, forms a pre-assembled unit that can be mounted uniformly on a housing of the connector part with the coolant lines and power lines already connected. This results in simple assembly of the connector part.

[0034] In one embodiment, the cooling unit has at least one busbar element that is connected to the at least one plug contact and to which the at least one load line is electrically connected within the flow space. For example, the busbar element is fixedly connected to a housing of the cooling unit, with an associated plug contact being fastened to the busbar element. The plug contact is thus held to the cooling unit via the busbar element. An associated load line is connected to the busbar element, such that the busbar element creates an electrical connection between the plug contact and the associated load line for transmitting charging currents between the plug contact and the load line.

[0035] In one embodiment, the at least one connection element has a first end and a second end. The at least one connection element is connected to a housing of the cooling unit at the first end, such that the connection element is fixed to the housing and the load line can extend through the feed-through channel into the housing of the cooling unit, and a flow connection also exists between the housing of the cooling unit and the coolant line via the coolant channel. At the second end remote from the first end, the connection element is beveled with respect to a longitudinal axis along which the connection element extends longitudinally and along which the feed-through channel and the coolant channel are formed in the body of the connection element. In the region of the second end, the connection element thus extends along a plane that is oblique to the longitudinal axis.Such a bevel allows the load cable to be easily inserted into the feedthrough channel for assembly purposes in order to electrically contact the load cable within the cooling unit with an associated plug contact.

[0036] In one embodiment, the connector part has two electrical plug contacts. The cooling unit forms two flow chambers, each of which is assigned to one of the plug contacts, through which coolant can flow. Each plug contact is connected, for example, via an associated busbar element to a housing part of the cooling unit, so that the plug contact is fixed to the cooling unit and a pre-assembled, uniformly mountable unit is created.

[0037] In one embodiment, the cooling unit has two connection elements, each assigned to one of the flow chambers and to each of which a coolant line is connected together with a load line. The connection elements each have a feed-through channel and a coolant channel, wherein the associated load line extends through the feed-through channel and coolant can flow through the coolant channel. Each plug contact is assigned a flow chamber for providing cooling to the plug contact. Each flow chamber is assigned a connection element, via which an associated coolant line, together with a load line guided therein, is connected to the cooling unit. The load line is connected to the associated plug contact, for example, via a busbar element.There is a flow connection between the coolant line and the flow chamber so that coolant can be directed between the flow chamber and the associated coolant line.

[0038] In one embodiment, an electrical load line extends into each of the flow spaces for electrical connection to an associated plug contact. Within the associated flow space, each plug contact is connected to an associated load line. The load line extends from the coolant line associated with the flow space via the connection element into the interior of the flow space and is contacted within the flow space, for example, with a busbar element connected to the plug contact, thus creating an electrical connection between the load line and the plug contact within the flow space.

[0039] The two plug contacts with the connected load lines can be used, for example, to transmit a charging current in the form of a direct current. The two plug contacts are arranged together on the cooling unit, with each plug contact being assigned a (separate) flow chamber that is in flow communication with an associated coolant line and via which an associated load line is connected to the respective plug contact.

[0040] In one embodiment, each flow chamber is assigned a further (second) coolant line to establish a coolant flow through the respective flow chamber. Coolant is supplied via one of the coolant lines, which serves as the supply line. Coolant is discharged via the other coolant line, which serves as the return line, resulting in a coolant flow through the respective flow chamber during operation.

[0041] The two plug contacts are generally at different potentials during operation, so it must be ensured that the plug contacts are sufficiently voltage-resistant and insulated from each other during operation. To prevent the electrical insulation from being impaired by a coolant flow, particularly when using a water-based coolant, the flow chambers are fluid-tightly separated from each other in one embodiment, so that a separate, electrically isolated coolant flow is provided via each flow chamber. The flow chambers defined within the cooling unit are thus separated from each other, so that a coolant flow only flows along one load line and along an associated plug contact, but does not come into contact with the other plug contact and the load line associated with the other plug contact.

[0042] A charging system for charging an electric vehicle comprises a plug connector part of the type described above. Such a charging system also comprises a mating connector part that can be plugged into the plug connector part. The plug connector part can, for example, implement a charging plug that is arranged on a charging cable, the component of which is the at least one electrical load line and the at least one coolant line. The mating connector part, on the other hand, can, for example, be arranged as a charging socket on the electric vehicle and connected to the plug connector part in the form of the charging plug. The charging plug can, for example, be connected to a charging station via the charging cable, so that when the plug connector part and the mating connector part are connected, charging currents can be transmitted from the charging station to the electric vehicle.

[0043] It is also conceivable that the connector part implements a charging socket on the side of an electric vehicle.

[0044] A connector part of the type described here can be used in particular for transmitting charging currents in the form of direct currents. However, such a connector part can also be used for transmitting charging currents in the form of alternating currents.

[0045] The concept underlying the invention will be explained in more detail below using the exemplary embodiment shown in the figures. They show:

[0046] Fig. 1 is a view of a charging station with a charging cable arranged thereon for connecting to an electric vehicle;

[0047] Fig. 2 is a view of an embodiment of a connector part in the form of a charging plug;

[0048] Fig. 3 another view of the connector part in the form of the charging plug;

[0049] Fig. 4 is a view of a plug-in section of the connector part with a cooling unit arranged thereon;

[0050] Fig. 5 is a view of the cooling unit with plug contacts arranged thereon;

[0051] Fig. 6 a view through the cooling unit without connected pipes;

[0052] Fig. 7 is a longitudinal sectional view through the cooling unit, along the line AA according to

[0053] Fig. 6, with a connected coolant line and an associated load line;

[0054] Fig. 8 is an enlarged view of connecting elements of the cooling unit; and

[0055] Fig. 9A-9E Views of a connection element of the cooling unit. Fig. 1 shows a charging system comprising a charging station 1, which serves to charge an electrically powered vehicle 4, also referred to as an electric vehicle. The charging station 1 is designed to provide a charging current in the form of an alternating current or a direct current and has a charging cable 2, which is connected at one end 201 to the charging station 1 and at another end 200 to a connector part 3 in the form of a charging plug.

[0056] In an embodiment illustrated in Figs. 2 and 3, the connector part 3 has two plug-in sections 300, 301 on a housing 30, via which the connector part 3 can be plugged into an associated mating connector part 5 in the form of a charging socket on the vehicle 4 along a plug-in direction E. In this way, the charging station 1 can be electrically connected to the vehicle 4 in order to transmit charging currents from the charging station 1 to the vehicle 4.

[0057] To enable rapid charging of the electric vehicle 4, e.g., during a so-called rapid charging process, the transmitted charging currents have a high current intensity, e.g., greater than 500 A, possibly even in the order of 700 A or more. Such high charging currents result in thermal losses at the charging cable 2 and also at the charging plug 3 and charging socket 5, which can lead to heating of the cable 2, the charging plug 3, and the charging socket 5.

[0058] The permissible heating of components of the charging system is limited by standards, for example to a maximum value of 50 K. This means that measures must be taken to prevent excessive heating during charging, especially when high currents, for example in the order of 700 A or more, are used.

[0059] In the connector part 3 in the form of the charging plug according to Fig. 2 and 3, plug contacts 31 A, 31 B are arranged on socket domes 302 on a lower plug section 300, which serve as load contacts for transmitting a charging current in the form of a direct current. When plugged into the associated mating connector part 5 in the form of the charging socket on the electric vehicle 4 side, the plug contacts 31 A, 31 B come into electrical contact with associated mating contact elements on the charging socket 5 side, so that a charging current can be transmitted from the charging station 1 to the electric vehicle 4. Plug contacts 32 are also arranged on an upper plug section 301, which can serve to transmit control signals and as a protective contact (PE contact).

[0060] In the illustrated connector part 3 in the form of the charging plug, active cooling is provided to absorb and dissipate heat on the charging cable 2 and in the area of ​​the plug contacts 31 A, 31 B carrying the charging current, in order to limit the heating on the connector part 3.

[0061] Fig. 4 to 8 show an embodiment of an assembly comprising a housing part with a section 300 of the connector part 3 formed thereon, and also a cooling unit 33, which is fastened to the housing part forming the plug-in section 300. Coolant lines 22A, 22B, 23A, 23B are connected to the cooling unit 33 in order to conduct coolant flows through flow spaces 333 within the cooling unit 33. Load lines 21A, 21B are routed within the coolant lines 23A, 23B, which are connected to associated plug contacts 31A, 31B on the plug domes 32A, 32B within the plug-in section 300 and via which charging currents can thus be conducted.

[0062] The load lines 21A, 21B are accommodated within the tubular coolant lines 23A, 23B and routed along the length of the charging cable 2 within a cable sheath 20 of the charging cable 2. The load lines 21A, 21B, formed, for example, by electrical stranded conductors, extend concentrically within the coolant lines 23A, 23B and can be surrounded by coolant within the coolant lines 23A, 23B.

[0063] Two flow spaces 333 are defined within the cooling unit 33, each of which is assigned to one of the load lines 21A, 21B, as can be seen from Fig. 7 for the load line 21A. Each flow space 333 is also assigned one of the coolant lines 22A, 22B, which serves as a supply line, and one of the coolant lines 23A, 23B, which serves as a return line, so that during operation a coolant flow F can be conducted through each flow space 333 in order to absorb and dissipate heat at the associated plug contact 31A, 31B and also along the associated load line 21A, 21B, and thus provide active cooling at the connector part 3 and also along the length of the charging cable 2.

[0064] Within the flow space 333, the respective load line 21 A, 21 B is connected to an associated busbar element 311 by connecting the load line 21 A, 21 B to the busbar element 311, for example, via a welded or crimped connection and thus being mechanically fixed to the busbar element 311 and also being electrically contacted.

[0065] The coolant lines 22A, 22B are connected to associated ports 331A, 331B of the cooling unit 33 and are each in flow communication with an associated flow chamber 333 via flow channels 332. Coolant can thus be introduced into an associated flow chamber 333 via the coolant lines 22A, 22B, which serve as the supply line, flow through the respective flow chamber 333, and can be discharged again via the coolant lines 23A, 23B, which serve as the return line, to flow along the associated load line 21A, 21B on the return path, thus removing heat from the area of ​​the connector part 3 and also from the area of ​​the load lines 21A, 21B. For each plug contact 31 A, 31 B, a coolant flow F results through the cooling unit 33 along the busbar element 311 and also along the connected load line 21 A, 21 B.

[0066] In the illustrated embodiment, each plug contact 31A, 31B has a contact section 310 forming a contact socket. The plug contacts 31A, 31B are arranged on the cooling unit 33, for example, by the plug contacts 31A, 31B each being fixed to an associated busbar element 311 and thus being secured to the cooling unit 33 via the busbar elements 311 and each being electrically contacted with one of the load lines 21A, 21B. Because the plug contacts 31A, 31B are fastened to the cooling unit 33, a preassembled module is created, as can be seen in Fig. 5. This assembly can be mounted uniformly on a housing part of the connector part 3 forming the plug-in section 300, so that a simple assembly of the plug contacts 31 A, 31 B with already connected load lines 21 A, 21 B and coolant lines 22 A, 22 B, 23 A, 23 B is achieved.

[0067] The coolant lines 23A, 23B with the load lines 21A, 21B accommodated therein are connected to the cooling unit 33 via connecting elements 34A, 34B. The connecting elements 34A, 34B each have a body 340 in the form of a grommet, which is connected by one end 344 to a housing 330 of the cooling unit 33 and onto which an associated coolant line 23A, 23B is slipped via an end 343 remote from the end 344, so that the body 340 engages in the respective coolant line 23A, 23B, as can be seen from the sectional view according to Fig. 7 in conjunction with the enlarged view according to Fig. 8. Each coolant line 23A, 23B can be fixed to the associated connection element 34A, 34B, for example by means of a clamp, so that the coolant line 23A, 23B is firmly and permanently connected to the associated connection element 34A, 34B in the ready-to-use state.

[0068] A feedthrough channel 341 and a coolant channel 342 are formed in the body 340 of the respective connecting element 34A, 34B, each extending along a longitudinal axis L through the body 340, as can be seen from the separate views of an individual connecting element 34A, 34B according to Figs. 9A to 9E.

[0069] The associated load line 21A, 21B is accommodated in the through-channel 341 and extends through the respective through-channel 341, starting from the coolant line 23A, 23B, into the associated flow space 333 in the interior of the housing 330 of the cooling unit 33, as can be seen from Fig. 8 in conjunction with Fig. 7.

[0070] In contrast, the coolant channel 342 creates a flow connection between the coolant line 23A, 23B and the associated flow space 333 inside the cooling unit 33, so that coolant can flow between the flow space 333 and the coolant line 23A, 23B. A flow cross-section is provided via the coolant channel 342 in the region of the connecting element 34A, 34B, so that coolant can flow between the flow space 333 and the inner lumen of the coolant line 23A, 23B, which accommodates the load line 21A, 21B, with a comparatively small pressure loss in the region of the associated connecting element 34A, 34B.

[0071] In the region of the end 343, the respective connecting element 34A, 34B is chamfered, in that the end 343 extends along a plane inclined to the longitudinal axis L, as can be seen in Fig. 90. Such a chamfer facilitates the insertion of the load line 21A, 21B into the associated connecting element 34A, 34BB and thus into the cooling unit 33 during assembly.

[0072] Because the respective load line 21A, 21B is accommodated in the through-channel 341 of the respective connecting element 34A, 34B, the load line 21A, 21B extends in a guided manner along the connecting element 34A, 34B and through the connecting element 34A, 34B. The load line 21A, 21B can be compressed within the through-channel 341, so that the load line 21A, 21B is accommodated in a compact manner on the connecting element 34A, 34B, thus leaving a sufficient flow cross-section for the coolant to flow.

[0073] As can be seen from the views according to Figs. 9A to 9E, the coolant channel 342 is formed, for example, in an angular sector, for example comprising an angle of approximately 90° around the longitudinal axis L, within the body 340 of the respective connecting element 34A, 34B. The coolant channel 342 extends along the entire length of the connecting element 34A, 34B and thus establishes a flow connection between the respectively connected coolant line 23A, 23B and the associated flow space 333 inside the housing 330 of the cooling unit 33.

[0074] The idea underlying the invention is not limited to the embodiments described above, but can also be implemented in other ways.

[0075] A connector part of the type in question here can implement a charging plug, for example on a charging cable, or a charging socket, for example on the side of an electric vehicle.

[0076] Such a connector part can be used, in particular, to transmit a charging current in the form of a direct current. However, it is also conceivable that the connector part is designed to transmit a charging current in the form of an alternating current.

[0077] Active cooling can be provided on one plug contact or on several plug contacts.

[0078] List of reference symbols

[0079] 1 charging station

[0080] 2 charging cables

[0081] 20 cable sheath

[0082] 200, 201 end

[0083] 21A, 21B load line

[0084] 22A, 22B Coolant line (supply)

[0085] 23A, 23B Coolant line (return)

[0086] 3 charging plugs

[0087] 30 housings

[0088] 300, 301 plug-in section

[0089] 302 socket dome

[0090] 31A, 31B plug contact

[0091] 310 Contact section

[0092] 311 Busbar element

[0093] 32 plug contacts

[0094] 33 Cooling unit

[0095] 330 housing

[0096] 331 A, 331 B connection

[0097] 332 flow channel

[0098] 333 Flow space

[0099] 34A, 34B connecting element

[0100] 340 bodies

[0101] 341 Feed-through channel

[0102] 342 coolant channel

[0103] 343 Beveled end

[0104] 344 End

[0105] E Insertion direction

[0106] F Coolant flow

Claims

Patent claims 1. An assembly of a charging system for charging an electric vehicle (4), comprising a plug connector part (3) having a plug-in section (300) for plugging into a mating plug connector part (5) and at least one electrical plug contact (31 A, 31 B) arranged on the plug-in section (300) for transmitting a charging current, at least one electrical load line (21 A, 21 B) which is electrically connected to the at least one plug contact (31 A, 31 B) for transmitting the charging current, and at least one coolant line (23 A, 23 B) in which the at least one electrical load line (21 A, 21 B) is guided and in which a coolant can flow around the at least one electrical load line (21 A, 21 B), characterized in that the plug connector part (3) has a cooling unit (33) having at least one connection element (34 A, 34 B) to which the at least one coolant line (23 A, 23B) together with the at least one load line (21A,21 B), wherein the at least one connection element (34A, 34B) has a feedthrough channel (341) and a coolant channel (342), wherein the at least one load line (21 A, 21 B) extends through the feedthrough channel (341) and coolant can flow through the coolant channel (342).

2. Assembly according to claim 1, characterized in that the at least one connection element (34A, 34B) has a body (340) within which the feedthrough channel (341) and the coolant channel (342) are formed.

3. Assembly according to claim 2, characterized in that the at least one coolant line (23A, 23B) is arranged on the body (340) so that the body (340) engages in the at least one coolant line (23A, 23B).

4. Assembly according to one of claims 1 to 3, characterized in that the cooling unit (33) forms a flow space (333) through which coolant can flow, wherein the flow channel (342) of the at least one connecting element (34A, 34B) is in flow connection with the flow space (333).

5. Assembly according to claim 4, characterized in that the at least one electrical load line (21A, 21B) for electrical connection to the at least one plug contact (31A, 31B) extends through the feedthrough channel (341) of the at least one connection element (34A, 34B) into the flow space (333).

6. Assembly according to claim 4 or 5, characterized in that at least one further coolant line (22A, 22B) is connected to the cooling unit (33) for establishing a coolant flow through the flow space (333).

7. Assembly according to one of the preceding claims, characterized in that the at least one plug contact (31 A, 31 B) is arranged on the cooling unit (33).

8. Assembly according to one of the preceding claims, characterized in that the cooling unit (33) has at least one busbar element (311) which is connected to the at least one plug contact (31 A, 31 B) and to which the at least one load line (21 A, 21 B) is electrically connected within the flow space (333).

9. Assembly according to one of the preceding claims, characterized in that the at least one connecting element (34A, 34B) is connected with a first end (344) to a housing (330) of the cooling unit (33) and is bevelled at a second end (343).

10. Assembly according to one of the preceding claims, characterized in that the plug connector part (3) has two electrical plug contacts (31 A, 31 B), wherein the cooling unit (33) forms two flow spaces (333) through which coolant can flow, each associated with one of the plug contacts (31 A, 31 B).

11. Assembly according to claim 10, characterized in that the cooling unit (33) has two connection elements (34A, 34B), each of which is assigned to one of the flow spaces (333) and to each of which a coolant line (23A, 23B) is connected together with a load line (21A, 21B), wherein the connection elements (34A, 34B) each have a feed-through channel (341) and a coolant channel (342), wherein the assigned load line (21A, 21B) extends through the feed-through channel (341) and coolant can flow through the coolant channel (342).

12. Assembly according to claim 10 or 11, characterized in that an electrical load line (21 A, 21 B) extends into one of the flow spaces (333) for electrical connection to one of the plug contacts (31 A, 31 B).

13. Assembly according to one of claims 10 to 12, characterized in that each flow chamber (333) is assigned a further coolant line (22A, 22B) for establishing a coolant flow through the respective flow chamber (333).

14. Assembly according to one of claims 10 to 13, characterized in that the Flow spaces (333) are separated from each other in a fluid-tight manner.

15. Charging system for charging an electric vehicle (4), with an assembly according to one of the preceding claims, wherein the plug connector part (3) is connected to a charging cable (2) and the at least one electrical load line (21 A, 21 B) and the at least one coolant line (23A, 23B) are components of the charging cable (2).

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