Connecting system and method for connecting the connecting system to a cable

Abstract

The invention relates to a connecting system (1) for connecting a conductor (5) of a cable (2) to a collector contact (7), the connecting system (1) comprising: - a conductor contact element (12) having: o a first connecting portion (13) for electrical connection to the conductor (5) of the cable (2); and, o a second connecting portion (14) for electrical connection to the collector contact (7), in order to ensure a simple, economical and efficient connection to the cable (2), and, according to the invention, the connecting system (1) comprises: - a contact element carrier (24) comprising: o a cooling chamber (8) through which a fluid can flow; o a fluid inlet connection (10) connected to the cooling chamber (8); and, o a fluid outlet connection (11) connected to the cooling chamber (8), the conductor contact element (12) being thermally coupled to the cooling chamber (8) in order to dissipate heat from the conductor contact element (12) to the fluid flowing through the cooling chamber (8).

Description

[0001] CONNECTION SYSTEM AND METHOD FOR CONNECTING THE CONNECTION SYSTEM TO A CABLE

[0002] AREA OF INVENTION

[0003] The present invention relates to a connection system for connecting a conductor of a cable to a consumer contact, the connection system comprising

[0004] - a conductor contact element with

[0005] o a first connection section for the electrical connection with the conductor of the cable as well as

[0006] or a second connecting section for the electrical connection with the customer contact.

[0007] Furthermore, the present invention relates to a method for connecting the connection system to a cable.

[0008] STATE OF THE ART

[0009] A conductor in a cable carrying an electric current generates heat – an unavoidable effect that reduces the efficiency of energy transmission. This heat generation, referred to as joules of power loss, arises from the resistance of the conductor material and the intensity of the current. The power loss increases with the square of the current – ​​doubling the current thus quadruples the heat generated.

[0010] To prevent overheating, two approaches are crucial: either limiting the current flow to minimize heat generation, or actively dissipating excess heat through cooling measures. Carefully planned thermal management is therefore essential, especially in high-current applications, to ensure efficient energy transfer.

[0011] To reduce the heat generated in conductors by current flow, cables with integrated cooling tubes are known from the prior art. In such a cable, a cooling tube typically runs centrally, surrounded by the conductor, thus enabling targeted dissipation of the generated heat. By transporting a fluid, such as water or another thermally conductive fluid, through the cooling tube, the conductor's temperature can be effectively regulated, even at high currents. This not only minimizes joule losses but also protects the material structure from thermal stress. Such cables are particularly important in applications where both efficiency and durability are essential. In particular, such cables can be used for charging electric vehicles.

[0012] In order to connect the cooled cables known from the prior art with a customer contact, for example with a contact pin of a plug, the central cooling tube in the connection area must be led away from the cable in order to make the conductor accessible so that it can be electrically coupled to the customer contact via a conductor contact element.

[0013] The necessary separation between the cooling tube and the conductor is problematic. Without the thermal connection to the cooling tube, the conductor and the conductor contact element in the connection area are no longer adequately cooled. This leads to a significant temperature increase in the connection area; that is, compared to the rest of the cooled cable, losses occur here that severely impair efficiency.

[0014] TASK OF INVENTION

[0015] It is therefore an object of the present invention to provide a connection system and a method for connecting the connection system to a cable that overcome the disadvantages of the prior art.

[0016] In particular, the connection system should ensure a simple, economical and efficient connection to the cable.

[0017] PRESENTATION OF THE INVENTION

[0018] This task is performed in a connection system for connecting a conductor of a cable to a consumer contact; the connection system encompasses...

[0019] - a conductor contact element with

[0020] o a first connection section for the electrical connection with the conductor of the cable as well as

[0021] a second connecting section for the electrical connection with the customer contact,

[0022] According to the invention, this is solved by the fact that

[0023] the connection system furthermore

[0024] - a contact element carrier with

[0025] o a cooling chamber through which a fluid can flow, o a fluid inlet connection connected to the cooling chamber for introducing the fluid into the cooling chamber, and

[0026] or a fluid outlet connection connected to the cooling chamber for draining the fluid from the cooling chamber

[0027] includes

[0028] wherein the conductor contact element is thermally coupled to the cooling chamber in order to transfer heat from the conductor contact element to the fluid flowing through the cooling chamber.

[0029] In summary, the connection system comprises the contact element carrier with the cooling chamber and the fluid inlet and outlet connections, as well as the conductor contact element.

[0030] The conductor contact element allows the cable conductor to be electrically connected to the customer contact. The customer contact can be a contact element of a plug, preferably a contact pin.

[0031] The conductor contact element can

[0032] - a length between 10mm and 50mm - a width between 10mm and 50mm as well as

[0033] - a height between 1mm and 5mm

[0034] exhibit. Furthermore, the conductor contact element can have any shape.

[0035] Preferably, the cross-section (perpendicular to a longitudinal extent) of the conductor contact element has a size between 10mm 2 and 250mm 2 , preferably between 50mm 2 and 250mm 2 , on .

[0036] The fluid inlet port and / or the fluid outlet port can each have a tube, in particular a mandrel-like or spigot-like tube, which is either integrally or detachably connected to the cooling chamber. Furthermore, it is conceivable that the fluid inlet port and / or the fluid outlet port is each designed as a bushing.

[0037] A supply pipe or a cooling pipe of the cable, preferably a cooling pipe located centrally within the cable, can be connected to the fluid inlet port. In any case, the fluid inlet port serves to introduce the fluid into the cooling chamber.

[0038] A drain pipe or the cable's cooling pipe, preferably the cooling pipe located centrally within the cable, can be connected to the fluid inlet port. In the latter case, the fluid then flows from the cooling chamber into the cable's cooling pipe. In any case, the fluid outlet port serves to drain the fluid from the cooling chamber.

[0039] The connection system according to the invention is used to cool the conductor contact element in order to ensure a lower temperature - even in the area of ​​the conductor contact element - despite a high current flow through the cable coupled to the customer contact via the conductor contact element.

[0040] In particular, the connection system can be used in the charging cable of an electric vehicle, preferably an electric car. Specifically, the connection system connects the corresponding charging cable to a plug. High voltages and currents sometimes occur during the charging of electric vehicles, which is why adequate cooling of the conductor contact element is essential. Using the connection system according to the invention, voltages in the range of 400 volts to 1200 volts and currents between 200 amperes and 3000 amperes, preferably between 500 amperes and 1500 amperes, can be realized or transmitted with virtually no loss.

[0041] Due to the thermal coupling between the conductor contact element and the cooling chamber, the conductor contact element is optimally cooled in an operating state.

[0042] Heat is transferred from the conductor contact element to the fluid flowing through the cooling chamber during operation, thus keeping the temperature of the conductor contact element low.

[0043] The operating state is the state in which the connection system is connected to the conductor of the cable, to an inlet pipe, in particular to the cooling pipe of the cable, and to an outlet pipe as well as to the consumer contact, i.e. the state in which, on the one hand, current can flow and, on the other hand, the fluid can flow.

[0044] Furthermore, the connection system according to the invention allows the cable to be connected to the system simply, quickly, and without significant material loss, particularly when the cable's cooling tube is connected to the fluid inlet port. With prior art solutions, a considerably longer section of the conductor typically has to be removed from the cooling tube when making the connection to the conductor contact element. This is completely eliminated with the connection system according to the invention. The conductor only needs to be guided to the conductor contact element coupled to the cooling chamber. Therefore, the use of the connection system increases the cable's cost-effectiveness.In order to enable the conductor contact element to be thermally coupled to the cooling chamber simply, quickly and reliably in practice, one embodiment of the invention provides that the contact element carrier comprises a contacting chamber in which the conductor contact element is arranged, wherein the contacting chamber

[0045] - at least an initial opening for the insertion of the cable conductor and

[0046] - at least a second opening to facilitate customer contact

[0047] exhibits .

[0048] Furthermore, the conductor contact element is also protected from environmental influences, such as moisture and / or mechanical stress, by the contact chamber.

[0049] The conductor of the cable and the customer contact are guided to the conductor contact element through the two openings of the contact chamber.

[0050] The first connection section and the second connection section are also protected by the contact chamber, so that the connection between cable and conductor contact element and the connection between conductor contact element and customer contact do not suffer any damage when the cable and the customer, preferably the plug, are subjected to stress or manipulation.

[0051] To ensure optimal heat transfer between the cooling chamber and the conductor contact element, it is advantageous for the conductor contact element to be located close to the cooling chamber. This allows as much heat as possible to be transferred to the fluid flowing through the cooling chamber during operation. Therefore, in a further embodiment of the invention, the contact chamber is arranged adjacent to the cooling chamber in such a way that a wall section of the cooling chamber simultaneously forms a wall section of the contact chamber. That is, the cooling chamber and the contact chamber share a wall section.

[0052] Preferably, the conductor contact element located in the contact chamber is arranged at least section by section on this wall section.

[0053] The wall section is at least partially covered by the contact chamber.

[0054] In addition to optimized heat transfer, this wall section also allows for material savings, making the connection system more economical to manufacture.

[0055] In a further embodiment of the invention, it is provided that the contacting chamber comprises two opposing receiving means, preferably strips or grooves, by means of which the conductor contact element can be guided and preferably fixed in the contacting chamber.

[0056] Using the receiving means, the conductor contact element can be inserted into the contacting chamber, preferably through the first opening.

[0057] Preferably, the holding means are manufactured with such precision that the conductor contact element is secured by the holding means in all directions. This also prevents the conductor contact element from slipping out of the contact chamber, especially through the first opening.

[0058] For example, the receiving means are strips that project from wall sections of the contacting chamber into the interior of the contacting chamber, or grooves that are formed in wall sections of the contacting chamber.

[0059] To make the connection system easy and economical to manufacture, a further embodiment of the invention provides that the cooling chamber and the contacting chamber are formed in one piece. This allows for material savings.

[0060] Furthermore, a one-piece manufacturing process is also advantageous because the cooling chamber and contact chamber do not need to be assembled separately when connecting the cable. This means that assembly time can be saved.

[0061] To ensure that the conductor contact element can be positioned easily and securely in the contact chamber, it can be advantageous if the contact chamber and the cooling chamber are separate during assembly of the connection system. The conductor contact element can then be inserted into the contact chamber independently of the cooling chamber. Therefore, in a further embodiment of the invention, the cooling chamber and the contact chamber are designed as two separate pieces and are positively connected to each other, preferably by means of a tongue-and-groove joint.

[0062] After the conductor contact element is positioned in the contact chamber and preferably already connected to the cable conductor and the customer contact, the contact chamber is connected to the cooling chamber. A tongue-and-groove connection, such as a click system, is preferably used for this purpose. This enables a simple and secure connection between the contact chamber and the cooling chamber.

[0063] In order to enable good heat transfer between the conductor contact element and the fluid during operation, a further embodiment of the invention provides that the cooling chamber is made of a plastic material, preferably a polymer matrix composite, and is preferably manufactured by injection molding. The plastic material can be a pure plastic or a plastic matrix containing fillers.

[0064] Preferably, it is a polymer matrix composite material comprising a filler, for example a plurality of short or continuous fibers and / or a plurality of particles, which are held together by a matrix of at least one polymer.

[0065] Preferably, glass fibers embedded in a polyamide 66 matrix are used. The thermal conductivity can be approximately 0.27 W / mK. The volume of the glass fibers can range between 25% and 50%.

[0066] To achieve optimal heat transfer, mineral or ceramic fillers can be embedded in a polymer matrix. The fillers can be in the form of particles and / or fibers. Examples of fillers include aluminum oxides, aluminum nitrides, silicon carbides, magnesium oxides, and / or aluminum silicates. These fillers are highly thermally conductive and can be embedded in a polyamide 66 matrix, which provides electrical insulation. With these combinations, optimal thermal conductivity of well over 0.27 W / mK can be achieved.

[0067] At least the wall section of the cooling chamber can be made of the plastic material, preferably of the polymer matrix composite material.

[0068] To manufacture the cooling chamber using a fully automated process and with high reproducibility, injection molding can be used. This makes the cooling chamber particularly economical to produce, as little or no post-processing is required. Furthermore, the surface structure can be precisely customized. In order to easily and reliably connect an inlet pipe, preferably the cooling pipe of the cable, and / or a drain pipe to the fluid inlet connection and / or the fluid outlet connection, a further embodiment of the invention provides that the fluid inlet connection and / or the fluid outlet connection each have a connection means.

[0069] The connecting element can be a hollow body, preferably a tube, which is either integrally manufactured with the cooling chamber or detachably connected to the cooling chamber.

[0070] In a further embodiment of the invention, the connecting means is designed as a pipe detachably connected to the cooling chamber, and the fluid inlet connection and / or the fluid outlet connection preferably each have a groove for receiving a sealing element.

[0071] To prevent fluid from escaping during operation, the fluid inlet port and / or the fluid outlet port can each have at least one groove in which a sealing element, preferably an O-ring, can be applied.

[0072] This design allows for easy connection of the inlet pipe and / or the outlet pipe, since the inlet and / or outlet pipe is first connected to a pipe, preferably a pipe is inserted section by section into the inlet and / or outlet pipe, and then the corresponding pipe is inserted section by section into the cooling chamber.

[0073] In a further embodiment of the invention, it is provided that the pipe

[0074] - a connection section for connecting to an inlet pipe or outlet pipe and

[0075] comprising an introduction section for insertion into the cooling chamber, wherein the connection section preferably has a pin profile on a surface.

[0076] This means that in the operating state the pipe is located section by section in the inlet or outlet pipe and section by section in the cooling chamber.

[0077] The connection section can have a spigot profile on the outer surface of the pipe. This is advantageous because the spigot profile seals and prevents fluid leakage, and also because it prevents the inlet or outlet pipe attached to the pipe from slipping or sliding off.

[0078] To minimize the number of individual parts in the connection system, a further embodiment of the invention provides that the connecting element is designed as a pipe formed integrally with the cooling chamber. This eliminates a step during assembly, as the pipe is already connected to the cooling chamber.

[0079] In order to ensure that the inlet pipe or the outlet pipe is reliably and securely connected and sealed to the pipe formed integrally with the cooling chamber, a further embodiment of the invention provides that the pipe includes a connection section for connection to an inlet pipe or outlet pipe, wherein the connection section has a pin profile on a surface.

[0080] To reduce flow losses and minimize fluid turbulence, a further embodiment of the invention provides that a central axis of the fluid inlet connection is aligned parallel, preferably coaxially, to a central axis of the fluid outlet connection. This makes the cooling of the conductor contact element even more efficient. The symmetrical alignment of the connections makes the design of the connection system more space-saving, which is particularly advantageous in confined installation conditions.

[0081] Furthermore, the coaxial alignment, in particular, can facilitate the integration of the connection system into existing cable and connector connections. Additionally, the parallel alignment of the center axes can better absorb mechanical stresses, such as compressive or tensile forces, and reduces potential stress points at connection points. Moreover, the alignment of the connections simplifies the installation of the inlet and outlet pipes and reduces the likelihood of incorrect installation.

[0082] In order to enable the connection system to be used even with spatially limited or specifically oriented cables, plugs and / or cooling circuits, a further embodiment of the invention provides that a central axis of the fluid inlet connection and a central axis of the fluid outlet connection lie in one plane and enclose an angle between 80° and 100°, preferably between 85° and 95°, particularly preferably 90°.

[0083] The angle range between 80° and 100° minimizes abrupt changes in fluid flow, thereby reducing turbulence. Despite this angle range, efficient cooling of the conductor contact element is ensured.

[0084] To ensure particularly good and efficient heat transfer between the conductor contact element and the fluid, a further embodiment of the invention provides that the conductor contact element is cuboid in shape and rests flat against a wall section of the cooling chamber. The second connecting section of the conductor contact element preferably has a bore into which the receiving contact, preferably a contact pin of a connector, can be inserted section by section to establish an electrical connection. The cuboid shape of the conductor contact element and its flat contact against a wall section of the cooling chamber achieve optimal thermal coupling. The flat contact also increases the stability of the conductor contact element, thereby reducing the risk of damage or loosening, for example, due to vibrations.Furthermore, the cuboid design of the conductor contact element allows for a space-saving construction of the cooling chamber and preferably the contacting chamber, making the connection system flexible and economical to produce.

[0085] The bore in the second connection section allows for easy and precise insertion of the customer contact, such as a contact pin of a plug. This simplifies assembly and ensures a reliable electrical connection. The bore can be designed to be compatible with different customer contacts, increasing the flexibility and applicability of the connection system in various power supply systems.

[0086] In a further embodiment of the invention, it is provided that the conductor contact element has a cross-section comprising two legs and a base section connecting the two legs in sections, wherein one leg lies flat against a wall section of the cooling chamber.

[0087] In particular, it is advantageous if the second connecting section has the aforementioned cross-section. Preferably, the cross-section is essentially U-shaped.

[0088] Electrical contact with the sensor contact can be established by inserting the sensor contact into the volume defined by the two legs and the base section. Preferably, the two legs are then pressed against the sensor contact. It is also possible that at least one of the two legs is glued, soldered, or welded to the sensor contact. It is also conceivable that the two legs are manufactured with such precision that simply inserting the sensor contact is sufficient for electrical contact.

[0089] It is conceivable that the first connecting section of this embodiment is manufactured in such a way that it can be guided and preferably fixed in the contacting chamber by means of the receiving means. Preferably, the first connecting section is cuboid in shape.

[0090] Furthermore, a power supply system comprising a connection system according to the invention and a cable is provided, wherein the cable

[0091] - a cooling pipe,

[0092] - a conductor surrounding the cooling pipe, at least in part, as well as

[0093] - comprising an outer sheath surrounding the conductor and the cooling tube, wherein the conductor is connected to the first connecting section of the conductor contact element and the receiver contact is connected to the second connecting section of the conductor contact element.

[0094] In the context of the invention, the cooling tube is understood to be a hollow body made of a flexible material, for example, plastic. Preferably, it is a hose-like cooling tube. In any case, the cable must remain flexible despite the cooling tube.

[0095] The cable conductor is connected to the conductor contact element by a material bond, a positive connection, and / or a force-fit connection. Preferably, the conductor is crimped, welded, soldered, or glued to the conductor contact element. However, it is also conceivable that the conductor is inserted or clipped into the conductor contact element. Preferably, the cable's cooling tube is connected to the fluid inlet port of the contact element carrier. However, it is also conceivable that the cable's cooling tube is connected to the fluid outlet port. Likewise, it is conceivable that neither the fluid inlet port nor the fluid outlet port is connected to the cooling tube, but rather to an external, separate cooling circuit.

[0096] Preferably, in the operating state, the fluid flows from the cooling tube of the cable via the fluid inlet connection into the cooling chamber and from the cooling chamber via the fluid outlet connection into a drain pipe, whereby the fluid is returned to the cooling tube via a cooling unit using the drain pipe.

[0097] For example, the cable's cooling pipe, the connection system, especially the cooling chamber, and the drain pipe can be connected to the cooling circuit of an electric vehicle. However, it can also be a separate cooling circuit from the electric vehicle, to which the connection system is connected.

[0098] Preferably, the conductor of the cable is led through the first opening into the contact chamber and the customer contact is led through the second opening into the contact chamber.

[0099] Regarding the advantages of the contact chamber, reference is made to the above statements.

[0100] To solve the problem mentioned at the outset, the invention also provides a method for connecting

[0101] - of a connection system comprising a contact element carrier and a conductor contact element, the contact element carrier comprising

[0102] a cold storage room,

[0103] a fluid inlet connection connected to the cooling chamber and

[0104] o one connected to the cooling chamber

[0105] Flui daus gangs ans chlussmit

[0106] - a cable, the cable encompassing

[0107] o a cooling pipe,

[0108] o a conductor surrounding the cooling pipe, at least in sections, as well as

[0109] o an outer sheath surrounding the conductor and the cooling pipe ,

[0110] provided for, the procedure comprising the following procedural steps:

[0111] - section by section exposing the conductor of the cable from the outer sheath ,

[0112] - possibly shortening the cooling pipe,

[0113] - Connecting the cooling pipe to the fluid inlet port of the contact element carrier,

[0114] - Connecting the conductor to the conductor contact element,

[0115] - Coupling the conductor contact element with the cooling chamber of the contact element carrier ,

[0116] - if necessary, connecting a drain pipe to the fluid outlet connection of the contact element carrier.

[0117] Regarding the advantages, especially concerning the connection of the cooling pipe to the fluid inlet port, reference is made to the above statements.

[0118] In order to optimally protect the conductor contact element, one embodiment of the method provides that the contact element carrier includes a contacting chamber, wherein the conductor contact element is inserted into the contacting chamber after being connected to the conductor and preferably fixed in order to thermally couple the conductor contact element with the cooling chamber.

[0119] BRIEF DESCRIPTION OF THE FIGURES

[0120] The invention will now be explained in more detail using exemplary embodiments. The drawings are exemplary and are intended to illustrate the inventive concept, but in no way to restrict it or even represent it exhaustively. They show:

[0121] Fig. 1 shows a schematic axonometric view of a first embodiment relating to a contact element carrier of a connection system according to the invention;

[0122] Fig. 2 is a schematic sectional view of the structure shown in Fig. 1.

[0123] first embodiment shown;

[0124] Fig. 3 shows a schematic axonometric view of a second embodiment relating to a power supply system;

[0125] Fig. 4 is a schematic sectional view of the structure shown in Fig. 3.

[0126] second embodiment shown;

[0127] Fig. 5 shows a schematic exploded view of a third embodiment relating to a power supply system;

[0128] Fig. 6 shows a schematic exploded view of the second embodiment;

[0129] Fig. 7 shows a schematic axonometric view of a fourth embodiment relating to a contact element carrier of the connection system according to the invention;

[0130] Fig. 8 shows a schematic axonometric view of a fifth embodiment relating to a contact element carrier of the connection system according to the invention;

[0131] Fig. 9 a schematic axonometric view of a sixth embodiment relating to a contact element carrier of the connection system according to the invention; Fig. 10 a schematic axonometric view of a seventh embodiment relating to two power supply systems;

[0132] Fig. 11 shows a schematic axonometric view of an eighth embodiment relating to a power supply system;

[0133] Fig. 12 shows a schematic exploded view of the seventh embodiment;

[0134] Fig. 13 shows a schematic exploded view of the seventh embodiment;

[0135] Fig. 14 shows a schematic axonometric view of the cable and conductor contact element of the seventh embodiment;

[0136] Fig. 15 shows a schematic axonometric view of the seventh embodiment;

[0137] Fig. 16 shows a schematic axonometric view of the contact element carrier of the seventh embodiment;

[0138] Fig. 17 shows a schematic axonometric view of the power supply system of the seventh embodiment;

[0139] Fig. 18 shows a schematic axonometric view of the power supply system of the seventh embodiment;

[0140] Fig. 19 a schematic axonometric view of the connection system of the seventh embodiment; Fig. 20 a schematic diagram relating to several temperature profiles;

[0141] Fig. 21 shows a schematic view of a cooling circuit.

[0142] WAYS TO IMPLEMENT THE INVENTION

[0143] Fig. 20 shows a schematic diagram in which temperature profiles occur at different connections of a cooled cable 2 with a defined cross-section (always 50 mm² in the connections shown). 2) with a customer contact 7, are shown. In general, it can be deduced that the temperature in the area of ​​the connection rises rapidly the further away a cooling element is.

[0144] Specifically, the first line concerns a temperature profile 29 in a connection known from the prior art, in which a cooling tube 4, centrally located in the cable 2, is led away from its central position from the cable 2 and the conductor contact element 12 approximately 5 cm before a conductor 5 of the cable 2 is connected to a conductor contact element 12. The temperature in the area of ​​the conductor contact element 12 rises to almost 250°C. In comparison, the temperature in the area of ​​the cooled cable 2 is approximately 85°C.

[0145] The second line also shows a temperature profile 30 for a connection known from the prior art, in which the cooling tube 4, centrally located in the cable 2, is moved away from its central position from the cable 2 and the conductor contact element 12 approximately 2.5 cm before the conductor 5 of the cable 2 is connected to the conductor contact element 12. The temperature in the area of ​​the conductor contact element 12 still rises to approximately 190°C.

[0146] The third line represents a temperature profile 31 for a connection system 1 according to the invention. Here, the temperature in the area of ​​the conductor contact element 12 rises by only 130°C. That is, compared to the temperature profile 29, the temperature in the area of ​​the conductor contact element 12 of the connection system 1 according to the invention is almost halved.

[0147] The connection system 1 according to the invention thus enables a high current flow through a cable 2 connected to a consumer contact 7 via a conductor contact element 12, while simultaneously maintaining a low temperature. This means that when using the connection system 1 according to the invention, losses are minimal.

[0148] The connection system 1 according to the invention comprises a contact element carrier 24 and the conductor contact element 12.

[0149] A first embodiment of the contact element carrier 24 is shown in Fig. 1 and Fig. 2, with Fig. 1 showing a schematic axonometric view and Fig. 2 a schematic sectional view. The contact element carrier 24 comprises a cooling chamber 8, a fluid inlet port 10 connected to the cooling chamber 8, and a fluid outlet port 11 connected to the cooling chamber 8. Above the cooling chamber 8 is a contacting chamber 9 in which the conductor contact element 12 can be arranged.

[0150] Specifically, the contact chamber 9 has two openings 22, 23, through which the conductor 5 of the cable 2 can be guided and through the second opening 23 the customer contact 7 .

[0151] The contact chamber 9 is arranged adjacent to the cooling chamber 8 such that the contact chamber 9 and the cooling chamber 8 share a wall section 15. The contact chamber 9 comprises two opposing receiving means 27, which in the first embodiment are designed as strips to guide and fix the conductor contact element 12. In the first embodiment, the contact chamber 9 and the cooling chamber 8 are formed in one piece and manufactured from a polymer matrix composite material by injection molding.

[0152] The fluid inlet port 10 and the fluid outlet port 11 each have a connecting means 3, which in the first embodiment is each designed as a pipe 16 formed integrally with the cooling chamber 8. Each pipe 16 comprises a connecting section 17 for connection to an inlet or outlet pipe, wherein the connecting section 17 has a pin profile 19 on an outer surface.

[0153] In the first embodiment, a central axis 20 of the fluid inlet port 10 and a central axis 21 of the fluid outlet port 11 are coaxially aligned.

[0154] Figures 3 and 4 show a second embodiment. The two figures schematically depict a power supply system comprising a connection system 1, a cable 2, and a consumer contact 7.

[0155] The connection system 1 of the second embodiment comprises a contact element carrier 24, which corresponds to the contact element carrier 24 shown in the first embodiment except for the following differences:

[0156] - In the second embodiment, the fluid inlet connection 10 is designed as a pipe 16 detachably connected to the cooling chamber 8.

[0157] - The pipe 16 of the fluid inlet connection 10 has the connection section 16 provided with the pin profile 19 and an insertion section 18 which projects into the cooling chamber 8. Furthermore, the fluid inlet connection 10 has two circumferential grooves 32 in which a sealing element, namely an O-ring, is arranged in each.

[0158] Furthermore, the connection system 1 includes the conductor contact element 12, which is arranged in the contacting chamber 9.

[0159] In the second embodiment, the conductor contact element 12 is cuboid in shape and lies flat against the wall section 15. For connection with the conductor 2 of the cable 2 and the receiver contact 7, the conductor contact element 12 has two connection sections 13, 14, namely the first connection section 13, to which the conductor 5 is connected, and the second connection section 14, which has a bore into which the receiver contact 7, designed as a contact pin of a plug, is inserted section by section.

[0160] The cable 2, connected to the conductor contact element 12 via the conductor 5, includes the centrally arranged cooling tube 4, which is surrounded by the conductor 5, which in turn is surrounded by an outer sheath 6.

[0161] The cooling pipe 4 is connected to the fluid inlet port 10, specifically to the connection section 17 of the pipe 16. This means that, in the operating state, the fluid flowing through the cooling pipe 5 is transferred to the cooling chamber 8 via the fluid inlet port 10 and then flows via the fluid outlet port 11 into a drain pipe (not shown) connected to the fluid outlet port 11.

[0162] Figure 6 shows a schematic exploded view of the second embodiment.

[0163] The exploded view shown in Fig. 5 (third embodiment) corresponds essentially to the schematic exploded view shown in Fig. 6 with the following difference: - The central axis 20 of the fluid inlet port 10 and the central axis 21 of the fluid outlet port 11 enclose an angle α of 90°.

[0164] Figs. 7, 8 and 9 each show a further embodiment of the contact element carrier 24.

[0165] Specifically, Fig. 7 shows a schematic axonometric view of a fourth embodiment, which relates to a contact element carrier 24 that essentially corresponds to the contact element carrier 24 of the first embodiment, with the following difference:

[0166] - the surface of the pipe 16 of the fluid inlet connection 10 is smooth and therefore does not have a pin profile 19 .

[0167] Fig. 8 shows a schematic axonometric view of a fifth embodiment, which relates to a contact element carrier 24 that essentially corresponds to the contact element carrier 24 of the first embodiment, with the following difference:

[0168] - The surface of the pipe 16 of the fluid inlet port 10 and the surface of the pipe 16 of the fluid outlet port 11 are each smooth. That is, both pipes 16 have no pin profile 19.

[0169] Fig. 9 shows a schematic view of a sixth embodiment, which relates to a contact element carrier 24 that essentially corresponds to the contact element carrier 24 of the first embodiment, with the following difference:

[0170] Both the fluid inlet port 10 and the fluid outlet port 11 are designed as bushings and therefore do not include a tube 16. The connection system 1 according to the invention can also be arranged in multiple parts, preferably in pairs, next to each other, wherein the multiple connection systems 1 are preferably surrounded and held together by a common shell 28.

[0171] Figure 10 (seventh embodiment) shows such an arrangement of two connection systems 1, which are surrounded by a common sheath 28. Specifically, Figure 10 shows a schematic axonometric view of two adjacent connection systems 1, each connected to the conductor 5 and the cooling tube 4 of a cable 2. That is, two power supply systems are visible in Figure 10.

[0172] Corresponding schematic exploded views are shown in Fig. 12 and Fig. 13. Additionally, a cable guide 33 is also visible in these exploded views, by means of which the cables 2 are held in position relative to each other, i.e., spaced apart from each other accordingly.

[0173] Each of these energy supply systems essentially corresponds to the energy supply system shown in Fig. 3 (second embodiment) with the following differences:

[0174] - The second connecting section 14 of the conductor contact element 12 of the seventh embodiment shown in Figs. 10, 12 and 13 is essentially U-shaped. That is, the second connecting section 14 has two legs 25 and a base section 26 connecting the legs 25.

[0175] - The first connecting section 13 of the conductor contact element 12, on the other hand, is cuboid in shape and can be guided and fixed in the contacting chamber 9 by means of the receiving means 27 .

[0176] In the assembled state of the energy supply systems, one of the two legs 25 lies flat against the wall section 15 of the cooling chamber 8, see in particular Fig. 13.

[0177] - The customer contact 7 is not shown in any of these figures. In the seventh embodiment, it can be inserted through the slot-shaped second opening 23 of the contacting chamber 9 into the receiving volume of the second connection section 14 defined by the two legs 25 and the base section 26 and contacted with the second connection section 14, in particular with the legs 25.

[0178] An axonometric detail view of the conductor contact element 12 connected to the conductor 5 of the cable 2 is shown in Fig. 14 and in Fig. 19.

[0179] Fig. 11 shows a schematic axonometric view of an eighth embodiment, which relates to a power supply system that is essentially the same as the power supply systems of the seventh embodiment, but has the following difference:

[0180] - the central axis 20 of the fluid inlet port 10 and the central axis 21 of the fluid outlet port 11 enclose an angle α of 90°.

[0181] Fig. 15 shows a schematic axonometric view of the seventh embodiment (two power supply systems), however, in comparison to e.g. Fig. 10, the shell 28 is not shown.

[0182] Fig. 16 shows an axonometric view of the contact element carrier 24 of the seventh embodiment.

[0183] Figures 17 and 18 each show an axonometric view of a single power supply system of the seventh embodiment. Figure 21 shows a schematic view of a power supply system integrated into a cooling circuit. The cooling circuit comprises a cooling unit 34, by means of which the fluid circulating in the cooling circuit is cooled. The cooling circuit can be a cooling circuit already present in an electric vehicle into which the power supply system has been integrated, or an external cooling circuit independent of an electric vehicle. REFERENCE SYMBOL LIST

[0184] Connection system

[0185] Cable

[0186] Connecting means

[0187] cooling pipe

[0188] Director

[0189] outer shell

[0190] Customer contact

[0191] Cold storage

[0192] Contact chamber

[0193] Fluid inlet connection

[0194] Fluid outlet connection

[0195] conductor contact element

[0196] first connecting section

[0197] second connecting section

[0198] Wall section of cold storage room 8

[0199] Pipe

[0200] Connection section

[0201] Introductory section

[0202] T-profile

[0203] Central axis of the fluid inlet port 10 Central axis of the fluid outlet port 11 First opening of the contacting chamber 9

[0204] second opening of the contact chamber 9 contact element carrier

[0205] Leg of the conductor contact element 12 Base section of the conductor contact element 12 Receiving means

[0206] Covering

[0207] Temperature profile of a connection system known from the prior art

[0208] Temperature profile of another connection system known from the prior art 31 Temperature profile of the connection system according to the invention 1

[0209] 32 Nut

[0210] 33 Cable routing

[0211] a Angle between the central axis 20 and the central axis 21

Claims

29 GODFATHER'S SAYINGS 1. Connection system ( 1 ) for connecting a conductor ( 5 ) of a cable ( 2 ) to a consumer contact ( 7 ), the connection system ( 1 ) comprising - a conductor contact element ( 12 ) with o a first connecting section ( 13 ) for electrical connection with the conductor ( 5 ) of the cable ( 2 ) as well as a second connecting section ( 14 ) for electrical connection with the customer contact ( 7 ) , characterized in that the connection system ( 1 ) further - a contact element carrier ( 24 ) with o a cooling chamber ( 8 ) through which a fluid can flow, o a fluid inlet connection ( 10 ) connected to the cooling chamber ( 8 ) for introducing the fluid into the cooling chamber ( 8 ) as well as a fluid outlet connection (11) connected to the cooling chamber (8) for the discharge of the fluid from the cooling chamber (8) comprising , wherein the conductor contact element ( 12 ) is thermally coupled to the cooling chamber ( 8 ) to transfer heat from the conductor contact element ( 12 ) to the fluid flowing through the cooling chamber ( 8 ).

2. Connection system (1) according to claim 1, characterized in that the contact element carrier (24) comprises a contacting chamber (9) in which the conductor contact element (12) is arranged, wherein the contacting chamber (9) - at least a first opening ( 22 ) for the insertion of the conductor ( 5 ) of the cable ( 2 ) and - at least a second opening ( 23 ) for carrying out customer contact ( 7 ) exhibits .30 3. Connection system (1) according to claim 2, characterized in that the contacting chamber (9) is arranged adjacent to the cooling chamber (8) such that a wall section (15) of the cooling chamber (8) simultaneously forms a wall section of the contacting chamber (9).

4. Connection system (1) according to any one of claims 2 to 3, characterized in that the contacting chamber (9) comprises two opposing receiving means (27), preferably strips or grooves, by means of which the conductor contact element (12) can be guided and preferably fixed in the contacting chamber (9).

5. Connection system (1) according to any one of claims 2 to 4, characterized in that the cooling chamber (8) and the contacting chamber (9) are formed in one piece.

6. Connection system (1) according to any one of claims 2 to 4, characterized in that the cooling chamber (8) and the contacting chamber (9) are formed in two pieces and are positively connected to each other, preferably by means of a tongue and groove connection.

7. Connection system ( 1 ) according to one of claims 1 to 6 , characterized in that the cooling chamber ( 8 ) is made of a plastic material, preferably of a polymer matrix composite material , and is preferably manufactured by injection molding .

8. Connection system (1) according to one of claims 1 to 7, characterized in that the fluid inlet connection (10) and / or the fluid outlet connection (11) each has a connecting means (3).

9. Connection system (1) according to claim 8, characterized in that the connecting means (3) is designed as a pipe (16) detachably connected to the cooling chamber (8) and the fluid inlet connection (10) and / or the fluid outlet connection (11) preferably each have a groove (32) for receiving a sealing element.

10. Connection system (1) according to claim 9, characterized in that the pipe (16) - a connection section ( 17 ) for connection to an inlet pipe or outlet pipe and - an introductory section ( 18 ) for introducing into the cold storage chamber ( 8 ) comprising, wherein the connection section (17) preferably has a pin profile (19) on a surface.

11. Connection system (1) according to claim 8, characterized in that the connection means (3) is designed as a tube (16) formed integrally with the cooling chamber (8).

12. Connection system (1) according to claim 11, characterized in that the pipe (16) comprises a connection section (17) for connection to an inlet pipe or outlet pipe, wherein the connection section (17) has a pin profile (19) on a surface.

13. Connection system ( 1 ) according to one of claims 1 to 12 , characterized in that a central axis ( 20 ) of the fluid inlet port ( 10 ) is aligned parallel, preferably coaxially , to a central axis ( 21 ) of the fluid outlet port ( 11 ).

14. Connection system (1) according to one of claims 1 to 12, characterized in that a central axis (20) of the fluid inlet port (10) and a central axis (21) of the fluid outlet port (11) lie in a plane and enclose an angle (a) between 80° and 100°, preferably between 85° and 95°, particularly preferably of 90°.

15. Connection system (1) according to one of claims 1 to 14, characterized in that the conductor contact element (12) is cuboid in shape and rests flat against a wall section (15) of the cooling chamber (8), wherein the second connection section (14) of the conductor contact element (12) preferably has a bore into which the recipient contact (7), preferably a contact pin of a plug, can be inserted section by section to establish an electrical connection.

16. Connection system ( 1 ) according to one of claims 1 to 14 , characterized in that the conductor contact element ( 12 ) has a cross-section comprising two legs ( 25 ) and a base section ( 26 ) connecting the two legs ( 25 ), wherein one leg ( 25 ) abuts a wall section ( 15 ) of the cooling chamber ( 8 ) in a planar position.

17. Power supply system comprising a connection system (1) according to any one of claims 1 to 16 and a cable (2), the cable (2) comprising - a cooling pipe ( 4 ) , - the conductor (5) surrounding the cooling pipe (4) at least in sections, as well as - an outer sheath (6) surrounding the conductor (5) and the cooling tube (4), characterized by the fact that the conductor ( 5 ) is connected to the first connecting section ( 13 ) of the conductor contact element ( 12 ) and the receiver contact ( 7 ) is connected to the second connecting section ( 14 ) of the conductor contact element ( 12 ).

18. Methods for joining - a connection system ( 1 ) comprising a contact element carrier ( 24 ) and a conductor contact element ( 12 ), the contact element carrier ( 24 ) comprising a cooling chamber ( 8 ) , o a fluid inlet connection (10) connected to the cooling chamber (8) and 33 o a fluid outlet port ( 11 ) connected to the cooling chamber ( 8 ) with - a cable ( 2 ) , comprising the cable ( 2 ) o a cooling pipe ( 4 ) , o a conductor (5) surrounding the cooling pipe (4) at least in sections as well as o an outer sheath (6) surrounding the conductor (5) and the cooling tube (4), the procedure comprises the following steps: - section by section exposing the conductor ( 5 ) of the cable ( 2 ) from the outer sheath ( 6 ) , - if necessary, shorten the cooling pipe ( 4 ) , - Connecting the cooling tube ( 4 ) to the fluid inlet port ( 10 ) of the contact element carrier ( 24 ) , - Connecting the conductor ( 5 ) to the conductor contact element ( 12 ) , - Coupling the conductor contact element ( 12 ) with the cooling chamber ( 8 ) of the contact element carrier ( 24 ), - if necessary, connecting a drain pipe to the fluid outlet connection ( 11 ) of the contact element carrier ( 24 ).

19. Method according to claim 18, characterized in that the contact element carrier (24) comprises a contacting chamber (9), wherein the conductor contact element (12) is inserted into the contacting chamber (9) after being connected to the conductor (5) and preferably fixed in order to thermally couple the conductor contact element (12) with the cooling chamber (8).

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