High-voltage connector with undercut

Abstract

The invention relates to a contact sleeve (1) for a high-voltage connector (2), comprising a first component (3) and a second component (4), wherein the contact sleeve (1) has a first end face (5) and a second end face (6) opposite the first end face (5), wherein the first component (3) is formed on the first end face (5), and the second component (4) is formed on the second end face (6), wherein the second component (4) has a contact surface (7) for a contact element (8) on the second end face (6) of the contact sleeve (1), wherein the first component (3) is inserted into the second component (4), wherein a portion of the first component (3) and a portion of the second component (4) are arranged on one another in such a way that they form an outer groove (9) for a seal (10), and wherein the second component (4) is designed to produce a snap-fit connection (11) with a snap-fit element (12), wherein the first component (3) forms an end stop (13) for the snap-fit element (12).

Description

[0001] P241415

[0002] - 1 -

[0003] High-voltage connectors with undercut

[0004] The invention relates to a contact sleeve for a high-voltage connector, a high-voltage connector and a motor vehicle with a battery and a high-voltage connector.

[0005] Contact sleeves for high-voltage connectors are known from the prior art. Contact sleeves can electrically connect two components, for example, a device and a battery. It may be necessary to separate the two components, for instance, to disconnect the device from the battery for maintenance purposes.

[0006] Contact sleeves with a metallic coating are known in the prior art. Partial coating of the contact sleeve is also known, but this makes manufacturing very complex.

[0007] Simple contact sleeves can be manufactured cost-effectively and in large quantities using the cold extrusion process. It may also be necessary for the contact sleeve to have undercuts, for example, for seals. It is known from the prior art to manufacture contact sleeves with undercuts using machining processes. However, this is very complex and expensive.

[0008] Based on this, the present invention aims to overcome, at least partially, the problems known from the prior art.

[0009] This problem is solved with the claimed contact sleeve, the high-voltage connector, and the motor vehicle. Further advantageous embodiments are specified in the dependent claims. The features described in the claims and in the description can be combined with one another in any technologically meaningful way. P241415

[0010] - 2 -

[0011] According to the invention, a contact sleeve for a high-voltage connector is presented. The contact sleeve comprises a first component and a second component. The contact sleeve has a first end face and a second end face opposite the first end face. The first component is formed on the first end face, and the second component is formed on the second end face. The second component has a contact surface for a contact element on the second end face of the contact sleeve. The first component is inserted into the second component. A section of the first component and a section of the second component are arranged adjacent to each other such that they form an external groove for a seal. The second component is configured to create a snap-fit ​​connection with a snap element. The first component forms an end stop for the snap element.

[0012] The contact sleeve serves to create an electrically conductive connection, in particular to electrically connect a contact element to a battery. However, the advantages described herein can generally be achieved in all electrical connections where a contact sleeve is used for high-voltage connections between two contact elements.

[0013] The contact sleeve comprises a first component and a second component. The contact sleeve can also be described as two-part. The contact sleeve has a first end face and a second end face opposite the first.

[0014] The contact sleeve is formed between the first end face and the second end face. The first and second end faces thus define the contact sleeve in an axial direction. The first end face can also be referred to as the first face or the first side. The second end face can also be referred to as the second face or the second side.

[0015] The first component is formed on the first end face, and the second component is formed on the second end face. A first end face and a second end face opposite the first end face do not mean that the end faces are end-face P241415

[0016] - 3 - are directly opposite each other, because the first end face and the second end face are each directed away from the contact sleeve.

[0017] The second component has a contact surface for a contact element on the second end face of the contact sleeve. Preferably, the contact surface on the second end face of the second component has a through-opening to the first component. Thus, the first component can be accessed from the second end face of the contact sleeve.

[0018] An electric current can be conducted with particularly low resistance across the contact surface. The contact surface is preferably designed to allow a contact element to be pressed onto it. This reduces the electrical resistance in the contact surface. The contact surface of the contact element preferably has the negative shape of the contact surface of the second component to enable ideal, planar contact.

[0019] The first component is inserted into the second component. Preferably, the second component is sleeve-shaped. Particularly preferably, the second component is tubular. The order in which the contact sleeve is assembled is not important. The second component can also be pushed onto the first component.

[0020] In this context, "inserted" means that at least part of the first component is encompassed by the second component. The first component can be inserted into the second component from the first end face of the contact sleeve towards the second end face of the contact sleeve.

[0021] The first component is preferably inserted into the second component to a predetermined depth. The insertion depth can be limited by a stop between the first and second components. P241415

[0022] - 4 -

[0023] This has the technical advantage that an electrically conductive connection can be established between the first component and the second component in the overlapping area between the first component and the second component.

[0024] The first component and the second component preferably form a contact zone in the overlapping area, so that an electrically conductive connection can be established between the first component and the second component.

[0025] A section of the first component and a section of the second component are arranged together to form an external groove for a seal. The first component and the second component can be configured such that together they provide an external groove for a seal. The section of the first component and the section of the second component are arranged together to form an external groove on the outer surface of the contact sleeve.

[0026] The second component is designed to create a snap-fit ​​connection with a snap element. Specifically, the second component is designed to create a snap-fit ​​connection with a snap element spaced apart on the second end face.

[0027] With a snap-fit ​​connection, a snap element can be positively connected to the second component and thus to the contact sleeve. The advantage of a snap-fit ​​connection is that it can be designed to be detachable. For this purpose, the snap element can be released from the snap-fit ​​connection and removed from the contact sleeve.

[0028] The first component forms an end stop for the snap element. The end stop prevents the snap element from being inserted further into the contact sleeve. This ensures that the snap element remains engaged in the snap-lock connection. However, it is not necessary for the end stop to be in direct contact with the snap element while the snap-lock mechanism is engaged. P241415

[0029] - 5 - The snap-fit ​​element is connected in the snap-lock connection. If the snap element is subjected to tensile stress, it engages positively with the second component. There may then be some play between the end stop and the snap element. If the snap element is subjected to sufficient compressive stress, it rests against the end stop of the first component. In this context, tensile stress refers to a force directed away from the contact sleeve, causing the snap element to engage. Sufficient compressive stress, in this context, refers to a force directed towards the contact sleeve, which in particular overcomes static friction forces between the snap element and the second component.

[0030] The feature that the second component is designed to create a snap-fit ​​connection with a snap element and that the first component forms an end stop for the snap element can also be described by the fact that the second component, together with the first component, forms an internal groove for a snap element at the end stop.

[0031] Alternatively, the feature “where the second component is designed to produce a snap-fit ​​connection with a snap element, wherein the first component forms an end stop for the snap element” can be replaced with “where a second section of the first component and a second section of the second component are arranged next to each other so that they form an internal groove for a snap element.”

[0032] Preferably, the inner groove has a base, a first side, and a second side. The second component forms the base and the second side of the inner groove.

[0033] The second side of the inner groove is then configured to engage with the snap element, and the first side of the inner groove is configured to form an end stop, in particular an axial stop, for the snap element. P241415

[0034] - 6 -

[0035] Preferably, the first component is inserted into the second component along a longitudinal axis of the contact sleeve until it reaches a stop. The first and second components form a circumferential outer groove in the outer surface of the contact sleeve at the stop. The longitudinal axis runs within the contact sleeve from the first end face to the second end face, or vice versa. Preferably, the longitudinal axis is a center line of the contact sleeve.

[0036] The stop between the first component and the second component can also be called the first stop. The end stop between the snap-in element and the first component can also be called the second stop.

[0037] Alternatively, the contact sleeve can also be described in the following way:

[0038] The first and second components are arranged on a common longitudinal axis of the contact sleeve. Together, they form a lateral surface of the contact sleeve. The first component is positioned at the first end face, and the second component is positioned at the second end face. The second component has a contact surface for a contact element on its second end face. The first component is inserted into the second component along its longitudinal axis up to a first stop. The first and second components form a circumferential groove in the lateral surface for a seal at the first stop. The second component is designed to create a snap-fit ​​connection with a snap element. The first component forms a second stop for the snap element.

[0039] The contact sleeve thus forms an outer groove for a seal and an inner groove for a snap-in element. However, these respective grooves are only made possible by the fact that the first component is inserted into the second component. Neither the first nor the second component forms a groove on its own. Only through the design of the first and second components and the arrangement of the two components according to the invention can the contact sleeve- P241415

[0040] - 7 - have undercuts in the form of an outside groove and an inside groove, without the first component and the second component having a groove on their own.

[0041] The first and second components can therefore be manufactured very efficiently using the cold extrusion process due to the absence of grooves and undercuts, respectively. Complex machining processes are not required.

[0042] Furthermore, the contact sleeve according to the invention has the advantage that the first component and the second component can be coated and processed independently of each other. A contact sleeve with partially different surfaces can only be manufactured so simply and efficiently due to the design of the first and second components.

[0043] In a preferred embodiment of the contact sleeve, the snap-lock connection is formed on an inner side of the second component. Preferably, the snap-lock connection is formed on an inner side of the second component spaced apart from the second end face.

[0044] The snap-fit ​​connection on the inside of the second component can be formed by an inwardly directed material projection. This material projection can extend, in particular, from the second end face towards the first end face. Such a material projection can be produced using cold extrusion.

[0045] The inner groove has a base, a first side, and a second side. The second component forms the base and the second side of the inner groove. In particular, the material projection forms the second side of the inner groove. The first side of the inner groove is formed by the first component. P241415

[0046] - 8 -

[0047] This embodiment has the advantage that the snap-lock connection is extremely space-saving.

[0048] In a further preferred embodiment of the contact sleeve, the outer groove has a base, a first side, and a second side. The first component forms the base and the first side of the outer groove. The second component preferably forms the second side of the outer groove.

[0049] This embodiment and the previous embodiment have the advantage that the contact sleeve can be manufactured by cold extrusion. Although the contact sleeve has a groove-shaped undercut, neither the first nor the second component has a groove-shaped undercut. The groove, and thus the undercut of the contact sleeve, is only formed when the first component is inserted into the second component. For this purpose, the second component forms the second side of the outer groove. The remaining outer groove is formed by the first component.

[0050] In a further preferred embodiment of the contact sleeve, the first component has an internal thread which is designed to provide a preload on the contact surface on the second end face of the second component by means of a screw connection of the contact element.

[0051] For this purpose, a screw of the contact element can be guided through the opening of the second end face. This embodiment has the advantage that the electrical contact resistance between the contact element and the second component can be reduced across the contact surface by means of the preload. Furthermore, the screw connection increases the connection reliability between the contact element and the contact sleeve.

[0052] Another advantage is that the preload increases the axial pressure from the first component to the second component, thus improving the electrical contact. P241415

[0053] - 9 - resistance between the first component and the second component can be reduced.

[0054] In a further preferred embodiment, the first component and the second component comprise copper. The second component is coated with tin and / or silver and / or nickel. Preferably, the second component is completely coated with tin and / or silver and / or nickel.

[0055] This embodiment has the advantage that the contact sleeve is partially coated, with only the second component being fully coated. The first component can remain uncoated to ensure reliable welding to, for example, a battery. This has the further advantage of allowing for particularly efficient partial coating of the contact sleeve. The coating offers the benefit of better protecting the second component from oxidation and simultaneously improving its contact resistance.

[0056] As a further aspect of the invention, a high-voltage connector is presented. The high-voltage connector comprises a contact sleeve, as described above, and a contact element with touch protection. The contact element is arranged on the contact surface of the second component and has a force-fit connection with the first component, which is designed to provide a preload on the contact surface at the second end face of the second component. The contact element has a snap-fit ​​element. The snap-fit ​​element engages with the second component of the contact sleeve. The snap-fit ​​element can additionally secure the contact element with the snap-lock connection.

[0057] Preferably, the snap element is part of the touch guard. The touch guard can encompass the snap element so that the snap element is attached to the touch guard at one end, with this end not being configured to engage with the contact sleeve. P241415

[0058] - 10 -

[0059] The described advantages and features of the contact sleeve are applicable and transferable to the high-voltage connector, and vice versa.

[0060] In a preferred embodiment of the high-voltage connector, the force-fit connection is a screw connection with an internal thread of the first component.

[0061] The contact sleeve is designed so that the contact element is pressed onto the contact surface of the second component, and the second component is held against the stop between the second component and the first component at the outer groove.

[0062] This embodiment has the advantage that the required preload can be generated between the contact sleeve and the contact element.

[0063] In another preferred embodiment of the high-voltage connector, a seal is arranged in the outer groove. Preferably, the contact guard of the contact element is slid over the contact sleeve with the seal.

[0064] The seal in the outer groove has the advantage of reducing the risk of moisture or dust penetrating to the contact surface between the contact element and the second component. Furthermore, it increases the protection of the contact sleeve against damage from moisture or dust.

[0065] As a further aspect of the invention, a motor vehicle with a battery and a high-voltage connector as described is presented. The battery is connected to the first component of the contact sleeve in a materially bonded and electrically conductive manner. A load is electrically connected to the contact element.

[0066] The described advantages and features of the high-voltage connector and the contact sleeve are applicable and transferable to the motor vehicle, and vice versa.

[0067] The first end face of the contact sleeve is preferably welded to a battery, and the second end face of the contact sleeve is connected to the contact element for a P241415

[0068] - 11 - connected to the user. Preferably, the first component of the contact sleeve is welded to the battery.

[0069] The invention is explained in more detail below with reference to the figures. The figures show a particularly preferred embodiment, to which, however, the invention is not limited. The figures and the size relationships shown therein are only schematic. They show:

[0070] Fig. 1 : Sectional view of a partial area of ​​a contact sleeve according to the invention,

[0071] Fig. 2: Schematic representation of a motor vehicle.

[0072] Fig. 1 shows a sectional view of a portion of a contact sleeve 1 according to the invention for a high-voltage connector 2. The contact sleeve 1 comprises a first component 3 and a second component 4. The contact sleeve 1 has a first end face 5 and a second end face 6 opposite the first end face 5. The first component 3 is formed on the first end face 5, and the second component 4 is formed on the second end face 6. The second component 4 has a contact surface 7 for a contact element 8 on the second end face 6 of the contact sleeve 1. The first component 3 is inserted into the second component 4. A section of the first component 3 and a section of the second component 4 are arranged such that they form an outer groove 9 for a seal 10. The second component 4 is designed with a snap-fit ​​connection 11 with a snap element 12 to create a snap-lock connection 11.The first component 3 forms an end stop 13 for the snap element 12. The snap-lock connection 11 is formed on an inner side of the second component 4.

[0073] The first component 3 is inserted into the second component 4 up to a stop 19. The first component 3 and the second component 4 form the circumferential outer groove 9 in the outer surface of the contact sleeve 1 at the stop 19. P241415

[0074] - 12 -

[0075] The outer groove 9 has a base 15, a first side 16, and a second side 17. The first component 3 forms the base 15 and the first side 16 of the outer groove 9. The second component 4 forms the second side 17 of the outer groove 9.

[0076] The inner groove 22 has a base 23, a first side 24, and a second side 25. The second component 4 forms the base 23 and the second side 25 of the inner groove 22. The second side 25 of the inner groove 22 is then configured to engage with the snap element 12, and the first side 24 of the inner groove 22 is configured to form an end stop 13 for the snap element 12.

[0077] The first component 3 has an internal thread 18 which is intended to provide a preload on the contact surface 7 on the second end face 6 of the second component 4 by means of a screw connection of the contact element 8.

[0078] The first component 3 and the second component 4 contain copper. The second component 4 is coated with tin.

[0079] Fig. 2 shows a schematic representation of a motor vehicle 20 with a battery 21 and a high-voltage connector 2. The high-voltage connector 2 comprises the contact sleeve 1 and a contact element 8 with touch protection. The contact element 8 is arranged on the contact surface 7 of the second component 4 and has a force-fit connection with the first component 3, which is designed to provide a preload on the contact surface 7 on the second end face 6 of the second component 4. The contact element 8 has a snap-fit ​​element 12. The snap-fit ​​element 12 engages with the second component 4 of the contact sleeve 1. The snap-fit ​​element 12 can additionally secure the contact element 8 with the snap-lock connection.

[0080] Battery 21 is materially and electrically connected to the first component 3 of contact sleeve 1. Contact sleeve 1 is connected to the battery with its first end face 5. P241415

[0081] - 13 - rie 21 is welded and connected to the second end face 6 with the contact element 8 for a consumer. The consumer 26 is electrically connected to the contact element 8.

[0082] P241415

[0083] - 14 -

[0084] List of reference signs

[0085] 1 contact sleeve

[0086] 2 high-voltage connectors

[0087] 3 first component

[0088] 4 second component

[0089] 5 first front

[0090] 6 second front

[0091] 7 Contact area

[0092] 8 Contact element

[0093] 9 outer groove

[0094] 10 Seal

[0095] 11 Snap-lock connection

[0096] 12 Snap-in elements

[0097] 13 End stop

[0098] 14 Inside

[0099] 15 Reason for the outer groove

[0100] 16 first side of the outer groove

[0101] 17 second side of the outer groove

[0102] 18 internal threads

[0103] 19 attacks

[0104] 20 motor vehicles

[0105] 21 Battery

[0106] 22 Inner groove

[0107] 23 Reason for the inner groove

[0108] 24 first side of the inner groove

[0109] 25 second side of the inner groove

[0110] 26 consumers

Claims

P241415 - 15 - Patent claims 1. Contact sleeve (1) for a high-voltage connector (2) comprising a first component (3) and a second component (4), wherein the contact sleeve (1) has a first end face (5) and one of the first end face (5) opposite second end face (6), wherein the first component (3) is formed on the first end face (5), and the second component (4) is formed on the second end face (6), wherein the second component (4) has a contact surface on the second end face (6) of the contact sleeve (1). (7) for a contact element (8), wherein the first component (3) is inserted into the second component (4), wherein a section of the first component (3) and a section of the second component (4) are arranged such that they form an outer groove (9) for a seal (10), and wherein the second component (4) is designed to produce a snap-lock connection (11) with a snap element (12), wherein the first component (3) forms an end stop (13) for the snap element (12).

2. Contact sleeve (1 ) according to claim 1 , wherein the snap-lock connection (11 ) is formed on an inner side (14) of the second component (4).

3. Contact sleeve (1 ) according to one of the preceding claims, wherein the outer groove (9) has a base (15), a first side (16) and a second side (17), wherein the first component (3) forms the base (15) and the first side (16) of the outer groove (9).

4. Contact sleeve (1) according to one of the preceding claims, wherein the first component (3) has an internal thread (18) which is designed to provide a preload on the contact surface (7) on the second end face (6) of the second component (4) by means of a screw connection of the contact element (8). P241415 - 16 - 5. Contact sleeve (1) according to one of the preceding claims, wherein the first component (3) and the second component (4) comprise copper, wherein the second component (4) is coated with tin and / or silver and / or nickel.

6. High-voltage connector (2) comprising a contact sleeve (1 ) according to one of the preceding claims and a contact element (8) with a touch guard (19), wherein the contact element (8) is arranged on the contact surface (7) of the second component (4) and the contact element (8) has a force-fit connection with the first component (3) which is intended to provide a preload on the contact surface (7) on the second end face (6) of the second component (4), wherein the contact element (8) has a snap element (12), and the snap element (12) is engaged with the second component (4) of the contact sleeve (1 ).

7. High-voltage connector (2) according to claim 6, wherein the friction-fit connection is a friction-fit screw connection with an internal thread (18) of the first component (3).

8. High-voltage connector (2) according to claim 6 or 7, wherein a seal (10) is arranged in the outer groove.

9. Motor vehicle (20) with a battery (21) and a high-voltage connector (2) according to one of claims 6 to 8, wherein the battery (21) is connected to the first component (3) of the contact sleeve (1) in a materially bonded and electrically conductive manner and a consumer (26) is electrically connected to the contact element (8).

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