CONNECTION ELEMENT FOR ELECTRICALLY CONNECTING A FLUID-COOLABLE INDIVIDUAL LINE, FLUID-COOLABLE INDIVIDUAL LINE UNIT, AND CHARGING CABLE
20220029329 · 2022-01-27
Assignee
Inventors
Cpc classification
B60L53/302
PERFORMING OPERATIONS; TRANSPORTING
H01R13/03
ELECTRICITY
H01R9/11
ELECTRICITY
H01R43/20
ELECTRICITY
B60L53/16
PERFORMING OPERATIONS; TRANSPORTING
F16L25/01
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Y02T90/14
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
Y02T10/70
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
Y02T90/12
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
Y02T10/7072
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
International classification
H01R13/00
ELECTRICITY
B60L53/16
PERFORMING OPERATIONS; TRANSPORTING
B60L53/302
PERFORMING OPERATIONS; TRANSPORTING
F16L25/01
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
H01R13/03
ELECTRICITY
H01R43/20
ELECTRICITY
Abstract
The invention relates to a connection element for electrically connecting an individual line which has a concentric conductor arrangement (32) and a central passage (33) for a cooling fluid. The connection element comprises an electrically conductive housing (2) with a sleeve-shaped pressing portion which is suitable for producing a press connection to the concentric conductor arrangement (32). The electrically conductive housing (2) here has an internal cooling passage (10) with a connection opening (11) for an external cooling line, said cooling passage leading into a space surrounded by the sleeve-shaped pressing portion. In addition, the connection element comprises a counterpressure element (3) which can at least partially lie in the space surrounded by the sleeve-shaped pressing portion. The counterpressure element (3) is furthermore configured to support the concentric conductor arrangement (32) on the inner side thereof when the sleeve-shaped pressing portion is compressed during the production of a press connection. The invention furthermore relates to a fluid-coolable individual line unit and to a charging cable having a charging connector.
Claims
1. A connection element (1) for electrically connecting an individual line which has a concentric conductor arrangement and a central channel for a cooling fluid, the connection element (1) comprising: a. an electrically conductive housing (2) b. having a sleeve-shaped compression section (6) which is suitable for producing a compression joint with the concentric conductor arrangement, c. wherein the electrically conductive housing (2) has an internal cooling channel (10) having a connection opening (11) for an external cooling line, said cooling channel leading into a space (12) surrounded by the sleeve-shaped compression section (6), d. wherein the connection element (1) furthermore comprises a counterpressure element (3), which can lie at least partially in the space (12) surrounded by the sleeve-shaped compression section (6), e. wherein the counterpressure element (3) is furthermore configured to support a concentric conductor arrangement on the inner side (40) thereof when the sleeve-shaped compression section (6) is compressed during the production of a compression joint, and is designed to be fluid-permeable in the pressed state in order to ensure a fluid connection through the counterpressure element (3).
2. The connection element as claimed in claim 1, wherein the counterpressure element (3) substantially has a cylindrical outer contour.
3. The connection element as claimed in claim 2, wherein the counterpressure element (3) is hollow-cylindrical and ensures fluid connection through a central through-opening (14).
4. The connection element as claimed in claim 2, wherein the counterpressure element (53) is arranged on the housing (52).
5. The connection element as claimed in claim 4, wherein the counterpressure element (53) is formed in one piece or as a single part with the housing (52).
6. The connection element as claimed in claim 1, the counterpressure element (3) of which is dimensioned in such a way that, as it is introduced, it can take along a support structure which is arranged in the central channel and which is directly enclosed by the conductor arrangement along the longitudinal extent.
7. The connection element as claimed in claim 1, wherein the counterpressure element (3) has a profile (16) on its outer casing (15), which profile permits a positive connection to the conductor arrangement during the production of the compression joint.
8. The connection element as claimed in claim 7, wherein the housing of the connection element (1) is produced from copper or a copper-containing alloy.
9. The connection element as claimed in claim 1, wherein the connection element (1) comprises a contact part (4), wherein the contact part (4) preferably has a female socket (20) which is suitable for use in a DC charging plug connector for an electric vehicle.
10. The connection element as claimed in claim 9, wherein the contact part (4) is coated with a wear-resistant, electrically highly conductive coating, wherein the coating is, in particular, a silver, gold or nickel platinum coating.
11. The connection element as claimed in claim 9, wherein the conductive contact part (4) is detachably connected to the housing (2) of the connection element (1).
12. The connection element as claimed in claim 11, wherein the conductive contact part (4) can be connected to the housing by means of a screw connection, wherein the housing (2) of the connecting element preferably has an internal thread (22), which can be screwed to an external thread (21) of the contact part.
13. The connection element as claimed in claim 1, wherein the internal cooling channel (10) opens axially into the space (12) surrounded by the sleeve-shaped compression section (6), preferably centrally with respect to the inner circumferential surface (7) of the sleeve-shaped compression section (6).
14. The connection element as claimed in claim 1, wherein the connection opening (11) is arranged perpendicularly to a connection direction of the individual line and preferably has an internal thread (13).
15. A fluid-coolable individual line unit (30, 50, 60) for a charging cable, which a) has a first connection element (1) according to claim 1, and b) an individual line (31) having a first and a second end, the individual line (31) comprising: a. a concentric conductor arrangement (32), b. insulation (37), i. wherein there is at least one central channel (33) for a cooling fluid, which is enclosed by the conductor arrangement (32), and ii. the insulation (37) directly encloses the conductor arrangement (32) and is impenetrable and electrically insulating for the cooling fluid (38), and iii. wherein the individual line (30, 50, 60) has a first stripped end piece (39) at its first end, on which the insulation (37) is axially set back with respect to the conductor arrangement (32), wherein the inner circumferential surface (7) of the compression section (6) of the first connection element (1) is in a radial compression joint with the conductor arrangement (32) on the stripped end piece (39), as a result of which an electrical connection between the connection element (1) and the concentric conductor arrangement (32), wherein furthermore c) a counterpressure element (3, 53, 63) is arranged in the central channel (33) so that it lies at least partially in the space (12) surrounded by the sleeve-shaped compression section (6), and supports the concentric conductor arrangement (32) on the inside thereof and, at the same time, is in a compression joint with the concentric conductor arrangement (32), d) wherein the counterpressure element (3, 53, 63) permits a fluid connection through the central channel (33) of the individual line (31) between the internal cooling channel (10) of the first connection element (1) and the second end of the individual line (31).
16. The fluid-coolable individual line unit (30, 50, 60) as claimed in claim 15, wherein the individual line (31) comprises a support structure (36, 86, 87), which is arranged in the central channel (33) and has a longitudinal extent which is directly enclosed by the conductor arrangement (32, 88, 88′) along the longitudinal extent, wherein the support structure (36, 86, 87) is arranged between the counterpressure element (3, 53, 63) and the second end of the individual line (31).
17. The fluid-coolable individual line unit (30, 50, 60) as claimed in claim 15, wherein the conductor arrangement (32, 88, 88′) can be penetrated by the cooling fluid (38) in the central channel (33).
18. The fluid-coolable individual line unit (30, 50, 60) as claimed in claim 15, which comprises a sealing means (45) which produces a fluidtight connection between the sleeve-shaped compression section (6) and the insulation (37) of the individual line (31), wherein the sealing means (45) preferably comprises a flexible hose, in particular a shrink-on hose.
19. The fluid-coolable individual line unit as claimed in claim 15, wherein a second connection element (89, 89′) is arranged at the second end of the individual line (73, 73′), wherein the second connection element (89, 89′) preferably comprises means for the electrical connection of the individual line (73, 73′) to an electric charging station (91), wherein the charging station is preferably a charging station for electric vehicles, and wherein the means for electrical connection is provided for connecting the fluid-coolable individual line (73, 73′) to a power connection (94, 94′) and/or to a terminal or plug system of the electric charging station (91).
20. A charging cable having a charging plug connector (80), comprising a first and a second fluid-coolable individual line unit (73, 73′) as claimed in claim 15, and a common protective sheath (85), wherein the charging plug connector (70) comprises a charging plug housing (71), preferably a charging plug housing (71) according to IEC 62196-3, wherein the charging cable is preferably a DC charging cable in which two DC connection pins (72, 72′) of the charging plug connector are implemented by the first connection elements (74, 74′) of the two individual lines (73, 73′).
21. The charging cable (80) as claimed in claim 20, wherein the charging cable (80) comprises at least one hose (75) made of a fluidtight material surrounded by the common protective sheath (85) and connected to at least one of the external cooling connections of the two first connection elements (74, 74′), wherein a cooling fluid passed through one of the central channels of the two fluid-coolable individual line units (73, 73′) can be returned in the opposite direction through the at least one hose (75).
22. A method for producing a fluid-coolable individual line unit (30, 50, 60) as claimed in claim 15, and wherein the method comprises the following steps: a) providing an individual line (31), which comprises a concentric conductor arrangement (32) and insulation (37), wherein there is in the individual line (31) at least one central channel (33) for a cooling fluid (38), which is enclosed by the conductor arrangement (32), and wherein the insulation (37) directly encloses the conductor arrangement (32) and is impenetrable and electrically insulating for the cooling fluid (38), b) providing a connection element (1), and c) stripping the individual line (31) at a first end, with the result that the first end has a first stripped end piece (39), on which the insulation (37) is axially set back with respect to the conductor arrangement (32), d) introducing, in particular screwing, the counterpressure element (3, 53, 63) into the central channel (33) of the individual line (31), e) pushing the sleeve-shaped compression section (6) of the connection element (1) onto the first stripped end piece (39), f) wherein the counterpressure element is introduced into the conductor arrangement (32) to such an extent that, after the sleeve-shaped compression section (6) has been pushed on, the conductor arrangement (32) and the sleeve-shaped compression section (6) completely enclose the counterpressure element (3, 53, 63), at least in a partial section, and g) producing a radial compression joint between the sleeve-shaped compression section (6) and the conductor arrangement (32) by means of a pressing tool in the region of the partial section, with the result that the counterpressure element (3, 53, 63) supports the conductor arrangement (32) toward the inside during the pressing operation.
23. The method as claimed in claim 22, a) wherein the individual line (31) furthermore comprises a support structure (36) having a longitudinal extent, b) the support structure is arranged in the central channel (33) and is directly enclosed by the conductor arrangement (32) along the longitudinal extent, c) wherein an optionally present longitudinal section of the support structure (33) is pushed back in the longitudinal direction as the counterpressure element (3, 53, 63) is introduced.
24. The method as claimed in claim 23, wherein the pushing on of the sleeve-shaped compression section of the connection element and the introduction of the counterpressure element (53) take place simultaneously.
25. The method as claimed in claim 22, wherein the pressing is carried out with a pressing tool which has a two-part hexagonal die.
26. The method as claimed in claim 22, wherein the pressing takes place at two different positions offset axially with respect to the compression sleeve (6).
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0079] In the drawings used to explain the exemplary embodiment:
[0080]
[0081]
[0082]
[0083]
[0084]
[0085]
[0086]
[0087]
[0088]
[0089]
[0090]
[0091]
[0092] In principle, identical parts are provided in the figures with the same reference signs.
WAYS OF CARRYING OUT THE INVENTION
[0093]
[0094] The electrically conductive housing 2 has a substantially cylindrical shape and is preferably produced from copper or a copper alloy. As an axial extension of a main section 5, it comprises a sleeve-shaped compression section 6. In the context of this application, this sleeve-shaped compression section is also referred to as a compression sleeve. This has a substantially constant wall thickness, for example a 2.5 mm wall thickness, before pressing. Only toward the open end is the wall thickness of the compression section tapered outwards at its inner circumferential surface 7, thereby simplifying the introduction of the concentric conductor arrangement of the individual line to be connected. In addition, owing to the larger inside diameter in this region, it is possible to partially accommodate the insulation of the individual conductor to be connected, thereby simplifying the sealing of the individual line from the outside.
[0095] The counterpressure element 3 has a substantially hollow-cylindrical shape. It is produced from a threaded pin made of stainless steel. The inside diameter of the central through-opening 14 of the counter-pressure element 3 is, for example, approximately 5 mm and the wall thickness of the hollow cylinder is, for example, approximately 2 mm. The dimensions must be selected in such a way that sufficient pressure resistance is ensured during pressing and the central through-opening is kept open even after pressing. On the outer circumferential surface 15, the counterpressure element has a structure which is formed by a helically formed groove 16 in the outer circumferential surface 15. At the front end, the outer circumferential surface 15 of the counterpressure element 3 has a chamfer 17, which simplifies the introduction of the counterpressure element 3 into the concentric conductor arrangement of the individual line.
[0096] The contact part 4 is produced from a copper-containing alloy. However, it can also be produced from other electrically highly conductive materials, in particular from electrically highly conductive alloys. The contact part of this exemplary embodiment is silver-coated. However, other wear-resistant, highly conductive compounds, such as gold and nickel-platinum coatings, are also suitable. The contact part forms a female socket 20 for mating with a pin-shaped contact. At the end opposite the socket 20, the contact part comprises a threaded bolt with an external thread 21. This is provided for screwing to the main section 5 of the housing 2. For this purpose, the main section comprises a blind hole 18 with an internal thread 22 on the side facing away from the compression section 6. For securing the screw connection, a spring ring (not shown) is used as screw locking device between the housing 2 and the contact part 4. A square profile 23 arranged on the contact part makes it possible to screw on the contact part 4 with a double open-end wrench. In order to prevent rotation of the housing 2 in a plug connector housing (not shown in
[0097]
[0098] However,
[0099]
[0100] However, this boundary is not sealed against cooling fluid, and therefore the cooling fluid 38 can spread in the radial direction as far as the insulation 37.
[0101] As can be seen from
[0102] In
[0103]
[0104]
[0105]
[0106]
[0107] A cross section through the DC charging cable 80 is shown in
[0108] The first and the second individual line 73, 73′ are arranged adjacent to one another and touch one another. The two cooling hoses 75, 75′, which return the cooling fluid of the individual lines 73, 73′, are each arranged in such a way that they are in contact with one of the individual lines 73 and 73′ and the neutral conductor 81. This results in a compact arrangement of all components of the DC charging cable 80 and of the two individual lines 73, 73′. In addition, there are eight contact points in this arrangement which support the insulation 85.
[0109] At an outside diameter of 31 mm, the DC charging cable has a conductor cross section of 35 mm.sup.2 and is designed to be able to transmit a continuous DC current of 700 A over 7 m without the surface temperature of the DC charging cable becoming hotter than 50° when cooled with water at a temperature of 20° C. and a flow rate of 1.81/min.
[0110]
[0111] The two individual lines 73, 73′ each comprise a first connection element 74, 74′ and a second connection element 89, 89′ at their two ends. The first connection elements 74, 74′ are arranged in the charging plug housing 71. Both connection elements each have a contact part 95, 95′ with a female socket. The cooling fluid cooled down by the DC charging station is supplied to both connection elements via the central channel of the respective individual line 73, 73′. The return takes place via the cooling hose 75, 75′ connected in each case to the connection opening of the first connection element 74, 74′. The individual lines 73, 73′ are each connected to the DC charging station 91 via a second connection element 89, 89′. The cooled cooling fluid is in each case supplied to the central channel of the respective individual line 73, 73′ via a fluid outlet line 93, 93′ and the respective connection opening of the second connection element 89, 89′. In this exemplary embodiment, the connection opening is embodied axially or parallel to the compression section of the respective second connection element 89, 89′. The second connection element 89, 89′ in each case has a means for the electrical connection of the respective individual line 73, 73′ to one of the two power connections 94, 94′ of the electric charging station, for example to a busbar.
[0112] In summary, it may be stated that a connection element has been provided which makes possible a mechanically robust and at the same time inexpensive connection to a fluid-cooled conductor which has a central fluid channel surrounded by a concentric conductor. The connection elements are suitable both for the connection of the charging connector to the individual lines and for the connection of the individual lines to a charging station. As a result, fluid-coolable DC charging cables become more robust and at the same time less expensive.