High-voltage round-contact plug connector

Abstract

The present invention relates to a high-voltage plug connector having a first plug end for the electrical contact-connection of a high-voltage printed circuit board or a high-voltage busbar, having a second connection end for the releasable electrical contact-connection to a further high-voltage component and having a connection portion that connects the first plug end and the second connection end to one another. The first plug end of the high-voltage plug connector has at least one round contact, wherein the round contact has a spring base, which is fixedly connected to the connection portion, and multiple lamellae arranged next to one another, extending from the spring base and projecting outwards towards an insertion point of the round contact. The invention furthermore relates to a high-voltage assembly having such a high-voltage plug connector and to a method for producing a high-voltage round-contact plug connector.

Description

[0001] High-voltage round contact connectors

[0002] The present invention relates to a high-voltage connector with a first plug end for electrically contacting a high-voltage circuit board or a high-voltage busbar, with a second connection end for detachable electrical contacting with another high-voltage component, and with a connecting section that interconnects the first plug end and the second connection end. Furthermore, the invention relates to a high-voltage assembly with such a high-voltage connector and a method for producing a high-voltage round-contact connector.

[0003] The trend towards electrification of mobility, energy supply, and industrial drives, combined with increasing power density, is leading not only to an increase in operating voltage but also to ever-increasing electrical currents, which must be distributed in corresponding high-voltage systems and supplied to and discharged again by suitable power electronics. Modern electric vehicles, for example, use powerful electric motors for propulsion. Their electrical energy is supplied by a high-voltage storage unit via a high-voltage system with associated power electronics and high-voltage busbars. In such a high-voltage system, the high-voltage storage unit is typically used as the electrical source, connected to both a high-voltage power supply and the electric motor via appropriate high-voltage busbars and the associated power electronics.In contrast to low-voltage systems, which are used in vehicle electrical systems as well as for controlling industrial drives and power electronics, high-voltage systems use direct voltages between 60 V and 1.5 kV or alternating voltages between 30 V and 1.0 kV. Since such high-voltage systems for innovative electromobility, energy supply, and industrial applications exceed the limits for electrical hazards to persons, increased safety requirements must be considered during the installation and operation of high-voltage systems to prevent unintentional contact and injury to persons.

[0004] For connecting a high-voltage storage unit to the high-voltage components of the power electronics and electric drive, as well as the components of the charging device, various connection technologies are generally known in high-voltage systems. For example, the connections between the individual components of the high-voltage system can be made using electrical cables and connectors. The advantage of electrical cables and connectors is that they allow for relatively flexible cable routing, quick disconnection / disassembly, and reliable protection against accidental contact. However, connectors typically have a limited current-carrying capacity and can therefore only be used up to certain currents.An alternative option, which can also be used for very high currents, is high-voltage busbars, which are connected to the other high-voltage components via screw connections or welded joints. Such screw connections have a relatively low contact resistance. The disadvantage of screw connections is the complex and rigid connection between the high-voltage components and the limited protection against accidental contact, so trained personnel and protective equipment are required, especially when servicing a high-voltage system.

[0005] For example, DE 10 2016 200451 A1 discloses a screw connection for a high-voltage system that provides electrical and mechanical contact between a high-voltage busbar and a high-voltage battery or other high-voltage components. This electrical screw connection has a multi-part, electrically insulating cover to protect people from contact with the electrical voltage of the high-voltage system and from the electrical current flowing through the screw connection. While this high-voltage screw connection offers sufficient protection against unintentional contact while simultaneously ensuring safe power transmission, both the manufacture and assembly of this screw connection are complex, and the connection is inflexible.

[0006] The present invention is therefore based on the object of providing an improved connection of high-voltage components which, in addition to cost-effective production, enables simplified and safe assembly of high-voltage systems and a safe electrical connection of high-voltage components.

[0007] The object underlying the invention is achieved in that the first plug-in end of the high-voltage connector has at least one round contact, wherein the round contact has a spring base that is firmly connected to the connecting section, as well as a plurality of adjacently arranged lamellae extending from the spring base, which protrude outwardly relative to a plug-in tip of the round contact. A crimp-free connection is considered, in particular, to be a detachable electrical contact between the second connection end of the connector and another high-voltage component, which enables a detachable plug-in or screw connection to another high-voltage component via a spring contact or a cable lug.Such a high-voltage round-contact connector enables the quick and easy creation of a high-voltage connection between the components of a high-voltage system, particularly between a high-voltage circuit board or a high-voltage busbar and another high-voltage component, which in turn can be a high-voltage circuit board or a high-voltage busbar. Such electrical contacting in a high-voltage system can be implemented with little effort and, thanks to the spring function of the lamellas, enables a certain tolerance compensation in the arrangement of the high-voltage components within the high-voltage system.

[0008] The term "high-voltage" is used in automotive engineering and energy supply for electrical systems that operate with alternating voltages above 30 V or direct voltage above 60 V. Accordingly, high-voltage systems are used not only in electrified vehicles but also in stationary systems in the energy industry to smooth peak loads and ensure grid stability. Compared to low-voltage systems, high-voltage systems have the advantage of a higher electrical voltage, meaning that only a relatively lower electrical current is required to generate the high electrical power needed to drive electric vehicles. This allows the cross-section of the busbars or conductors to be reduced, thus saving material and weight and reducing cooling requirements.The integration of high-voltage systems in motor vehicles requires a structural design adapted to the vehicle due to the associated safety requirements for necessary air and creepage distances as well as the limited space available in modern motor vehicles. At the same time, it also requires complex assembly with corresponding problems for automated and error-free installation.

[0009] The high-voltage round contact connector according to the invention enables rapid assembly and electrical contacting of the high-voltage components in a high-voltage system. The at least one round contact at the first plug-in end allows both easy disassembly of the components of the high-voltage system and reuse of these components for subsequent assembly. Two or more round contacts can also be provided at the first plug-in end of the connector to transmit high currents. The simple design of the round contact, designed as a laminar cage with several laminations arranged side by side and projecting outwards, enables a direct plug-in connection to a high-voltage printed circuit board (PCB) with direct electrical contact between the laminations and the high-voltage printed circuit board (PCB) without damaging or deforming the printed circuit board itself.The lamellae of the round contact generally run parallel to the plug-in axis of the first plug-in end, and the outwardly projecting curvature of the lamellae extends radially toward the plug-in axis, enabling the spring-loaded design of the round contact. This arrangement allows the connector to be later manufactured as a cost-effective stamped / bent component.

[0010] A preferred embodiment provides that the second connection end for the detachable electrical contact with another high-voltage component is designed as a second plug-in end, preferably as a second plug-in end with a round contact. The provision of a second plug-in end on the high-voltage round-contact connector also enables fast, secure electrical contact with the other high-voltage component at the second connection end. A second plug-in end designed as a round contact can in turn have a plurality of adjacently arranged lamellae extending from a spring base, which are firmly connected to the connecting section via the spring base.

[0011] In practice, each round contact can have at least 5, in particular at least 6, preferably at least 8 lamellae arranged next to one another, wherein the lamellae extending between the spring base and the insertion tip are arranged evenly around the circumference of the round contact and curved outwards. The lamellae, which project outwards in a radial direction and are spring-loaded relative to the spring base of the round contact, can achieve a relatively evenly distributed, good plug-in behavior as well as good mechanical and electrical contact with the high-voltage component through the distribution of the individual lamellae around the circumference of the round contact or the spring base. The lamellae, which are pre-loaded outwards in a radial direction, i.e. perpendicular to the insertion direction of the connector, enable damage-free assembly even on a high-voltage circuit board and nevertheless enable problem-free transmission of a high current density via the electrical contact.The pre-tensioning of the slats not only ensures damage-free assembly but also better contact behavior under vibration loads, which typically occur in vehicles.

[0012] For secure arrangement and pre-tensioning of the lamellae, the round contact can have an insert ring at the insertion tip, with the adjacent lamellae extending between the spring base and the insert ring and having an outwardly projecting curvature. The lamellae are connected to the spring base and the insert ring in such a lamella cage and together form a stable unit that is easy to handle during assembly of the high-voltage connector according to the invention. The insert ring further enables secure arrangement and even distribution of the individual lamellae at the contact of the first plug end and, if necessary, also at the second connection end, thus also enabling secure electrical contact and mechanical fixation of the plug ends in the corresponding contact openings of the high-voltage components.The insert ring and the spring base of the round contact are preferably ring-shaped, so that the outwardly projecting lamellae firmly connected to them achieve a good outwardly directed spring effect in addition to an even distribution of the lamellae at the first plug-in end or the second connection end. The width of the lamellae is essentially constant in the insertion direction of the round contact. Furthermore, the insert ring can be designed as a complete ring element in order to connect the adjacent lamellae in a torsion-proof manner. If the round contact is designed as a stamped and bent component, the insert ring can be closed except for a butt seam between the rolled ends of the stamped-out part that are rolled towards each other. The insert ring expediently has a smaller diameter than the diameter of the bore to be contacted. Due to this fact, it also functions as an insertion aid during assembly.(e.g. blind assembly or assembly by a robot).

[0013] A useful design provides for the curvature of the adjacent lamellae to be at least one times the material thickness of the lamellae, preferably at least one and a half times the material thickness of the lamellae. The curvature of the lamellae of a round contact is defined here as the difference between the distance of the spring base, which typically has the same diameter as a plug-in ring, and the maximum height of the outwardly projecting curvature of the lamellae in a direction perpendicular to the longitudinal axis or plug-in axis of the round contact of the high-voltage connector. Relative to the average diameter of the spring base, the curvature is typically at least 10%, preferably at least 15%.In addition to providing sufficient tolerance compensation during electrical contact between the plug contact and a high-voltage component, the outwardly projecting curvature of the adjacent lamellae also facilitates insertion of the first plug end into a contact opening during connector assembly. To ensure secure contact between the round contact and a contact opening in the high-voltage component, the curvature should be selected such that the contact area of ​​the curvature of the lamella and the contact opening in a corresponding high-voltage component is at least 25% of the surface area of ​​the respective lamella, preferably approximately 50%.

[0014] An alternative embodiment provides that the adjacent lamellae of the round contact between the spring base and the plug-in ring are arranged at an angle to the insertion direction of the round contact, i.e., the longitudinal axis or plug-in axis. The inclined arrangement of the lamellae extending between the spring base and the plug-in ring increases the elasticity of the plug-in contact in the insertion direction and simultaneously enlarges the contact area of ​​the lamellae with respect to a contact opening in an associated high-voltage component. Embodiments of the round contact with inclined lamellae at an angle of at least 20° to the longitudinal axis of the round contact, preferably of up to 45° in the insertion direction, are conceivable, wherein the angle specified here refers to a straight line between the connection points of the lamellae on the spring base and the plug-in ring.A special variant provides that the round contact has a stop to limit the insertion depth of the plug end into a contact opening of a high-voltage component. Such a stop allows secure positioning and fixing of the first plug end in a contact opening of a high-voltage component in the insertion direction, so that inadvertent excessive insertion or pushing through of the connector through this contact opening is reliably prevented and removal of the plug end from the contact opening is only possible in the opposite direction to the insertion direction. The provision of a stop to limit the insertion depth also makes it possible to define a designated position of the first plug end in the contact opening. This means that during assembly of the high-voltage system, a first high-voltage component equipped with a round contact connector can be connected to a second high-voltage component by means of a further simple plugging process.This enables quick and cost-effective electrical contacting and mechanical connection of a high-voltage system, especially during the assembly of electric vehicles. Such a stop can be designed as one or more laterally protruding lugs in the area of ​​the connecting section or the round contact.

[0015] While a lug that protrudes outward relative to the circumference of the round contact is relatively easy to manufacture and allows the respective plug end to engage securely in a contact opening, a lug that protrudes on one side can also cause the connector to inadvertently tilt relative to the high-voltage component, which can lead to the required clearance being insufficient and thus to the failure of the plug contact. Furthermore, stops designed as laterally protruding lugs require a certain distance from the outwardly protruding lamellae of the round contact, so that a relatively large penetration depth of the round contact into the corresponding contact opening is necessary before such a laterally protruding stop can limit the insertion depth of the first plug end.

[0016] In a further embodiment, the round contact can have an annular recess on the adjacently arranged lamellae. After the first or a correspondingly designed second plug end of the high-voltage connector has been installed in an associated contact opening, the lower section of the lamellae in the region of the annular recess protrudes from an edge of the contact opening and thus effectively prevents the round contact from being pushed further through this contact opening. The annular recess creates a resistance or an increased holding force in the region of the edge of the contact opening that is significantly greater than the insertion force required to insert a second plug end into another contact opening. The high-voltage connector can advantageously be designed as a separate component, preferably as a one-piece component.Such separate connectors not only enable secure and simple contacting of high-voltage components, but also compensate for manufacturing tolerances of the high-voltage components and thermal expansion during operation of the high-voltage system. For this purpose, the first plug end and, if necessary, a second plug end of the separate high-voltage round contact connector are designed to be plugged into corresponding contact openings of high-voltage circuit boards and / or high-voltage busbars in order to provide secure electrical contact between the connector and the respective high-voltage component, depending on the shape of the contact openings. Furthermore, a connector designed as a separate component simplifies the complexity of high-voltage systems and their assembly, thus enabling not only automated and error-free assembly but also significantly reducing the costs of manufacturing a high-voltage system.The one-piece design of the high-voltage connector further reduces the number of components required to provide and establish electrical contact between the high-voltage components of a high-voltage system. Furthermore, identical components can be used for comparable high-voltage connections, reducing both the production and storage costs of the high-voltage connectors.

[0017] A practical design of the high-voltage connector provides for the round contact to be manufactured as a punched and bent component, in particular as a punched and bent laminar cage. The production of a round contact with laminations or of a laminar cage as a punched and bent component enables simple and cost-effective production of the plug end or the entire connector from a metal sheet or a metal strip, while maintaining good and consistent quality. In a punched and bent round contact, a butt seam results between the bent-together roller ends of the punched-out sheet, which typically extends axially parallel to the longitudinal axis of the round contact or to the longitudinal axis of the laminar cage. The bent-together roller ends are usually not connected to one another in the area of ​​the butt seam. To provide good mechanical and electrical properties, the round contact orThe high-voltage connector must be made of metal, preferably a copper alloy. In addition to being suitable as a stamped and bent component and providing the spring preload of the round contact for secure electrical contact with the high-voltage components, a copper alloy can be used to ensure good electrical conductivity of the connector and / or the round contact itself, in particular high-performance alloys CuNiSi or CuCrZr, etc., in order to provide good spring-elastic properties in addition to good electrical conductivity. Alternatively, the metal strip or metal sheet can also be made of a composite material, with one part made of copper and the other of aluminum. Using such an overlapping plated strip material, the plug ends or the round contacts on the plug ends can be made of different materials with different properties.Furthermore, with suitable materials and correspondingly inexpensive manufacturing processes, other possibilities for the formation of a high-voltage connector are also conceivable, for example by means of injection molding technology or laser cutting.

[0018] The present invention further relates to a high-voltage assembly with a first high-voltage component, a high-voltage printed circuit board or a high-voltage busbar, and a further high-voltage component, preferably a high-voltage printed circuit board or a high-voltage busbar, and with one of the high-voltage plug connectors described above, wherein the first high-voltage component has a contact opening in which the at least one round contact of the first plug end of the high-voltage plug connector is received, and wherein the laminations of the round contact form a high-voltage connection between the first high-voltage component and the high-voltage plug connector. Each contact opening in a high-voltage component is itself electrically conductive, for example coated with metal or formed from metal, in order to form a direct electrical contact with the laminations of the round contact.The high-voltage assembly according to the invention enables reliable, tolerance-compensating electrical contact between a high-voltage printed circuit board or a high-voltage busbar and other high-voltage components. Furthermore, the round contact, designed with adjacent lamellae or as a lamella cage, enables simple plug-in assembly without crimping or other plastic deformation to form the connection to the high-voltage printed circuit board or a high-voltage busbar. The high-voltage connector is easily positioned relative to the contact openings and, even when assembled, is three-dimensionally movable within limits to compensate for corresponding manufacturing and assembly tolerances in up to three planes.Furthermore, electrical contacting via a high-voltage connector requires very little space on the high-voltage circuit board or high-voltage busbar for the contact opening, with the round contact, designed as a lamella cage or provided with lamellas, reliably preventing damage to the high-voltage circuit board or high-voltage busbar. At the same time, direct electrical contacting of the high-voltage connector with a high-voltage circuit board or high-voltage busbar using the lamella-containing round contact enables direct contacting and the transmission of high current densities of up to 1000 A. The essentially round geometry of the round contact enables self-alignment of the plug end in the contact opening, with both the insertion tip of the round contact and a chamfer of the contact opening providing easy insertion assistance for the first plug end.In addition to the direct formation of the contact opening in a respective high-voltage component, a socket can also be pressed in there, which can improve the contact to the high-voltage component and can form an insertion stop through a base.

[0019] A practical embodiment of the high-voltage assembly provides that the second connection end of the high-voltage connector is designed as a second plug-in end with a round contact, and that the round contact of the second plug-in end is received in a contact opening of the further high-voltage component, wherein the lamellae of the round contact form a high-voltage connection between the second high-voltage component and the high-voltage connector. Such a high-voltage assembly with a high-voltage round contact connector designed as a pure plug-in element allows for secure and permanent electrical contacting of multiple high-voltage components, in particular a connection between multiple high-voltage circuit boards or multiple high-voltage busbars, with an inherently simple design and low assembly effort.Overall, this creates a secure high-voltage connection for transmitting high current densities between the various high-voltage components of a high-voltage assembly.

[0020] Furthermore, the present invention relates to a suitable method for producing an electrically conductive high-voltage round contact plug connector, in particular for a high-voltage assembly with a first high-voltage component and a second high-voltage component. This method comprises punching a flat punched part from a metal sheet including a first plug end and a second connection end, in particular adjacent lamellae at a first end of the flat punched part, preferably at a first end and a second end of the flat punched part, the subsequent embossing of the flat punched part to arch the adjacent lamellae towards the outside of the round contact and / or a stop, and the final bending or rolling of the first plug end into a round contact. The unwound, unembossed form of the high-voltage plug connector is considered to be the flat punched part here.Such a punching and bending process allows for the very cost-effective production of high-voltage connectors for the electrical contacting of high-voltage components. This process enables the fully automated and cost-effective production of such high-voltage connectors, which enable a secure electrical connection between the individual high-voltage components of the high-voltage system during assembly of high-voltage systems without additional components or with only a few additional components. When punching the flat punched part, the contact areas are provided on the end faces of the flat punched part. These areas have free roller ends on the sides opposite in the rolling direction, which, after bending or rolling of the flat punched part, lie opposite each other in round contact at a butt seam. Punching the flat punched part from a metal sheet does not automatically include the final separation of the punched part from the sheet metal strip.The actual separation or punching of the stamped part can take place either before or after stamping to form the spring-loaded round contacts.

[0021] Non-limiting embodiments of the present invention are explained in more detail below with reference to exemplary drawings.

[0022] Figure 1 is a side view of a high-voltage connector according to the invention,

[0023] Figure 2 is a perspective top view of another embodiment of a high-voltage connector according to the invention,

[0024] Figure 3 is a perspective view of a high-voltage assembly according to the invention with the high-voltage connector according to the invention from Figure 1,

[0025] Figure 4 is a perspective view of another high-voltage assembly according to the invention,

[0026] Figure 5 is a perspective view of another high-voltage assembly according to the invention,

[0027] Figure 6 is a plan view of a flat stamped part for bending a high-voltage connector according to the invention as shown in Figure 1, and

[0028] Figure 7 is a perspective view of the bending process of the first plug end of a high-voltage connector according to the invention to form a round contact with inclined lamellae.

[0029] Figure 1 shows a side view of a high-voltage connector 1 according to the invention for a high-voltage assembly 2, having a first plug-in end 3 for electrically contacting a first high-voltage component 5 of the high-voltage assembly 2 and a second connection end 4 for electrically contacting a second high-voltage component 5. The high-voltage connector 1 is designed as a separate, one-piece plug-in element which, in addition to the first plug-in end 3, also has a connection end 4 designed as a second plug-in end 6. The first plug-in end 3 and the second plug-in end 6 are each designed as round contacts 7 with outwardly projecting lamellae 8. The lamellae 8 extend parallel to the plug-in direction SR between a spring base 9 and an insertion ring 10 at the respective insertion tip in the plug-in direction SR of the round contacts 7.The outer edges of the insertion ring 10 in the plug-in direction SR are chamfered to facilitate insertion into a contact opening.

[0030] The spring-loaded and outwardly curved lamellae 8 are evenly distributed around the circumference of the annular spring base 9 and the insertion ring 10 and, together with the spring base 9 and the insertion ring 10, form a spring-loaded lamella cage. An increasing number of lamellae 8 running alongside one another in the longitudinal direction of the round contact 7 improves both the mating behavior of the round contacts 7 and the electrical contact with the contact openings 11 on the high-voltage components 5 of the high-voltage assembly 2. Typically, at least five, preferably at least six or eight individual lamellae 8 are provided to enable good mating behavior and good electrical contact with the contact opening 11.The round contacts 7 of a high-voltage connector 1 according to the invention can be manufactured in different dimensions depending on the requirements of a high-voltage connector 1 according to the invention, wherein one of the smallest useful variants has a diameter of the spring base 9 of 4.0 mm, with five outwardly projecting lamellae 8 and a material thickness of the round contact 7 of 0.6 mm.

[0031] The round contacts 7 of the first plug end 3 and the second plug end 6 at the connection end 4 are firmly connected to a connecting section 12 opposite the slats 8 on the spring base 9 in order to together form a separate, one-piece plug element. The spring base 9 is connected to the wide central section 14 of the connection section 12 via a narrow connecting piece 13. The wide central section 14 of the connection section 12 enables cooling of the high-voltage plug connection 1, whereby the cooling can be enhanced by further adapting the shape of the central section 14. Furthermore, the central section 14 can be used to integrate or arrange suitable sensors, for example to detect the temperature of the high-voltage plug connection 1 or to measure the applied current or the voltage difference between the high-voltage components 5 in order to thus determine the resistance of the high-voltage plug connection 1.A low resistance of the high-voltage connector 1 indicates good electrical contact between the round contact 7 and the contact openings 11, while a high resistance indicates a problem with the electrical contact. The center section 14 can also be used to rotate the round contacts 7 relative to each other.

[0032] The perspective top view in Figure 2 shows a further embodiment of a high-voltage plug connector 1 according to the invention with a first plug end 3 and a connecting end 4 designed as a second plug end 6. The two plug ends 3, 6 are again designed as round contacts 7 with resiliently outwardly curved lamellae 8. The round contacts 7 are each connected directly to a connecting section 12 at their spring base 9, wherein the connecting section 12 is designed without a connecting web 13. In contrast to the embodiment of a high-voltage plug connector 1 from Figure 1, the lamellae 8 are aligned inclined to the plug-in direction SR with an inclination of approximately 30° between the projection of a connecting line of the lamellae 8 between their connection points on the spring base 9 and on the plug-in ring 10 relative to a plug-in axis in the plug-in direction SR.

[0033] Figure 3 shows a perspective view of a high-voltage assembly 2 with a high-voltage plug connector 1 according to Figure 1. The round contact 7 at the first plug end 3 is plugged into a contact opening 11 on a first high-voltage busbar 15, and the round contact 7 at the second plug end 6 is plugged into a contact opening 11 on a second high-voltage busbar 15. The individual lamellae 8 of the round contacts 7 are each plugged into the corresponding contact openings 11 of the two high-voltage busbars 15 with the plug-in ring 10 at the plug end, so that the lamellae 8 protrude both on the top side of the high-voltage busbar 15 and on the underside of the high-voltage busbar 15. Accordingly, the lamellae 8 are in good electrical contact with the inner circumferential surface of the contact opening 11 across the entire thickness of the high-voltage busbar 15.At the same time, a good mechanical connection is formed between the round contacts 7 and the high-voltage busbars 15, wherein the plug ends 3, 6 are aligned essentially perpendicularly or only slightly inclined relative to the contact opening 11. Alternatively, instead of the high-voltage busbars 15, one or more high-voltage printed circuit boards 16 can also be used in a high-voltage assembly 2 according to the invention, so that with a high-voltage plug connector 1 according to the invention, not only electrical contact between a high-voltage busbar 15 and a high-voltage printed circuit board 16, but also electrical contact between several high-voltage busbars 15 or several high-voltage printed circuit boards 16 is possible.

[0034] Figure 4 shows a further embodiment of a high-voltage plug connector 1 according to the invention. For the transmission of high current intensities, as shown in the perspective view in Figure 4, four round contacts 7 are provided on the first plug end 3, which are arranged in corresponding contact openings 11 of a high-voltage circuit board 16. The round contacts 7, provided with lamellae 8, are each connected at their spring base 9 to the central part 14 of a connecting section 12 via a connecting web 13. On the central part 14 of the connecting section 12, a plurality of S-shaped spring contacts 17 are provided to form the second connecting end 4. These spring contacts 17 are arranged opposite one another and prestressed towards one another in order to jointly hold and electrically contact a high-voltage rail 15 as a plug contact.

[0035] Figure 5 shows a further embodiment of a high-voltage connector 1 according to the invention with four round contacts 7, which together form a first plug-in end 3 and are arranged in corresponding contact openings 11 of a high-voltage printed circuit board 16. These round contacts 7 are in turn connected via connecting webs 13 to the central part 14 of a connecting section 12. In this case, an annular bore 18 is provided in the central part 14 of the connecting section 12, which, as an annular shoe, enables screwed contact with another high-voltage component 5.

[0036] A method for producing a high-voltage connector 1 designed as a separate plug-in element according to Figure 1 is explained below with reference to Figures 6 and 7. A copper alloy, for example, is used as a suitable material for producing a high-voltage connector 1 according to the invention, preferably a high-performance copper alloy, e.g. CuNiSi or CuCrZr, which is provided as a flat sheet or as strip material. A flat, developed contour of the high-voltage connector 1 is then first punched from this sheet material, which is referred to as a flat punched part 19. The flat punched part 19 can be further connected to the sheet material to facilitate subsequent stamping, with punching out only taking place after stamping. However, the flat punched part 19 can also be separated from the sheet material at the same time as the contour of the flat punched part 19 is punched.Figure 6 shows a view of the flat stamped part 19, clearly showing the adjacent lamellae 8 of the resilient round contacts 7 at the first plug end 3 and the second plug end 6, as well as the connecting section 12 arranged therebetween. Following the stamping of the flat stamped part 19, the flat stamped part 19 is embossed. During embossing, not only the adjacent lamellae 8 of the resilient round contacts 7 are formed or preformed, but also, if necessary, circumferential depressions on the lamellae, a stop on the connecting section 12, or an offset in the region of the connecting section 12. In particular, the embossing of the flat stamped part 19 serves to bulge the adjacent lamellae 8 towards the outer side of the round contacts 7 in order to form a resilient contact region on the two plug ends 3, 6 of the high-voltage connector 1.If the separation of the flat stamped part 19 from the metal sheet or strip material was not already integrated during the punching of the contour of the flat stamped part 19, the separation of the flat stamped part 19 takes place after stamping. The contact areas of the plug ends 3, 6 are then bent into round contacts 7, see Figure 7, wherein the curved, adjacent lamellae 8 on the outside of the round contacts 7 protrude resiliently relative to the annular spring base 9 and the annular insert ring 10. The rolling ends 20 provided on the sides of the plug ends 3, 6 in the longitudinal direction of the high-voltage connector 1 face one another as a result of the bending of the round contact 7 and together form a butt seam 21, wherein the rolling ends 20 in the butt seam 21 of the round contacts 7 are preferably arranged parallel to one another in the radial direction.

[0037] Figure 7 shows the various individual steps in bending or rolling the first and second plug ends 3, 6 into a round contact 7. First, the lateral rolled ends 20 are bent and then the adjacent areas of the plug ends 3, 6 are gradually integrated into the bending process in order to achieve the roundest possible shape for the round contacts 7 and to arrange the rolled ends 20 parallel to one another in the butt seam 21. Corresponding to the embodiment of a high-voltage plug connector 1 shown in Figure 2, in the illustration of a round contact 7 shown in Figure 7, the lamellae 8 are aligned at an angle to the central axis of the round contact 7 in the plugging direction.

[0038] List of reference symbols:

[0039] 1 high-voltage connector

[0040] 2 high-voltage assembly

[0041] 3 first plug end

[0042] 4 Connection end

[0043] 5 High-voltage component

[0044] 6 second plug end

[0045] 7 round contact

[0046] 8 slats

[0047] 9 Spring base

[0048] 10 insert ring

[0049] 11 Contact opening

[0050] 12 connecting section

[0051] 13 Connecting bridge

[0052] 14 Middle section

[0053] 15 high-voltage busbar

[0054] 16 High-voltage circuit board

[0055] 17 spring contacts

[0056] 18 ring bore

[0057] 19 flat punched part

[0058] 20 rolling

[0059] 21 Butt seam

[0060] SR plug direction

Claims

Claims 1. High-voltage plug connector (1) with a first plug end (3) for electrically contacting a high-voltage printed circuit board (16) or a high-voltage busbar (15), with a second connecting end (4) for detachable electrically contacting a further high-voltage component (5), and with a connecting section (12) which connects the first plug end (3) and the second connecting end (4) to one another, characterized in that the first plug end (3) has at least one round contact (7), the round contact (7) having a spring base (9) which is firmly connected to the connecting section (12), and a plurality of lamellae (8) which extend from the spring base (9) and are arranged next to one another and which protrude outwards relative to a plug-in tip of the round contact (7).

2. High-voltage connector (1) according to claim 1, characterized in that the second connection end (4) for the detachable electrical contact with a further high-voltage component (5) is designed as a second plug end (6), preferably as a second plug end (6) with a round contact (7).

3. High-voltage connector (1) according to claim 1 or 2, characterized in that each round contact (7) has at least 5, preferably at least 8 lamellae (8) arranged next to one another, wherein the lamellae (8) extending between the spring base (9) and the insertion tip are arranged uniformly on the circumference of the round contact (7) and are curved outwards.

4. High-voltage connector (1) according to one of claims 1 to 3, characterized in that the round contact (7) has an insertion ring (10) at the insertion tip, wherein the adjacently arranged lamellae (8) extend between the spring base (9) and the insertion ring (10) and have an outwardly projecting curvature.

5. High-voltage connector (1) according to claim 4, characterized in that the curvature of the adjacently arranged lamellae (8) is at least one times the material thickness of the lamellae (8), preferably at least one and a half times the material thickness of the lamellae (8).

6. High-voltage connector (1) according to claim 4 or 5, characterized in that the adjacently arranged lamellae (8) of the Round contact (7) between the spring base (9) and the insertion ring (10) are arranged inclined to the plug-in direction (SR) of the round contact (7).

7. High-voltage connector (1) according to one of claims 1 to 6, characterized in that the round contact (7) has a stop for limiting the insertion depth of the plug end (3, 6) into a contact opening (11) of a high-voltage component (5).

8. High-voltage connector (1) according to one of claims 1 to 7, characterized in that the round contact (7) has an annular circumferential recess on the adjacently arranged lamellae (8).

9. High-voltage connector (1) according to one of claims 1 to 8, characterized in that the high-voltage connector (1) is designed as a separate component, preferably as a one-piece component.

10. High-voltage connector (1) according to one of claims 1 to 9, characterized in that the round contact (7) is manufactured as a stamped and bent component, in particular as a stamped and bent laminar cage.

11. High-voltage assembly (2) with a first high-voltage component (5), a high-voltage printed circuit board (16) or a high-voltage busbar (15), and a further high-voltage component (5), preferably a high-voltage printed circuit board (16) or a high-voltage busbar (15), and with at least one high-voltage plug connector (1) according to one of claims 1 to 9, characterized in that the first high-voltage component (5) has a contact opening (11) into which the at least one round contact (7) of the first plug end (3) of the high-voltage plug connector (1) is received, the lamellae (8) of the round contact (7) forming a high-voltage connection between the first high-voltage component (5) and the high-voltage plug connector (1).

12. High-voltage assembly (2) according to claim 11, characterized in that the second connection end (4) of the high-voltage plug connector (1) is designed as a second plug end (6) with a round contact (7), and the round contact (7) of the second plug end (6) is received in a contact opening (11) of the further high-voltage component (5), wherein the lamellae (8) of the round contact (7) form a high-voltage connection between the second high-voltage component (5) and the high-voltage plug connector (1).

3. A method for producing an electrically conductive high-voltage round contact connector (1), in particular for a high-voltage assembly (2) with a first high-voltage component (5) and a second high-voltage component (5), comprising the steps: Punching a flat punched part (19) from a metal sheet including a first plug-in end (3) and a second connecting end (4), in particular of lamellae (8) running alongside one another at a first end of the flat punched part (19), preferably at a respective first end and a second end of the flat punched part (19); Embossing the flat stamped part (19) to arch the adjacent lamellae (8) towards the outside of the round contact (7) and / or a stop; and Bend the first plug end (3) into a round contact (7).

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