HIGH-VOLTAGE CABLE SET

Abstract

A high-voltage cable set, in particular for a vehicle electrical system, contains a plurality of cables, which are surrounded by a common shield, and a connector, which consists of a conducting material and is electrically connected to the shield. For this purpose, a contact sleeve is integrated into the connector, the shield being fastened to the contact sleeve. The risk of contact corrosion is thereby significantly reduced.

Claims

1. An high voltage (HV) cable set, comprising: a common shield; a number of cables surrounded by said common shield; a contact sleeve; and a connection piece composed of a conductive material, said connection piece being electrically connected to said common shield by virtue of said contact sleeve being integrated into said connection piece, said contact sleeve fastened to said common shield.

2. The HV cable set according to claim 1, wherein said contact sleeve is manufactured from material whose electrochemical standard potential differs by no more than 0.05 V, from that of a material of said common shield.

3. The HV cable set according to claim 1, wherein said connection piece is manufactured from aluminum.

4. The HV cable set according to claim 1, wherein said common shield is manufactured as a braid composed of a multiplicity of tin-plated copper wires.

5. The HV cable set according to claim 1, wherein said contact sleeve is manufactured from brass.

6. The HV cable set according to claim 1, wherein said connection piece is formed as a cast part and said contact sleeve is partially encapsulated by casting in said connection piece.

7. The HV cable set according to claim 1, wherein said common shield is cohesively connected to said contact sleeve.

8. The HV cable set according to claim 1, wherein said contact sleeve is seated in a longitudinal direction in said connection piece.

9. The HV cable set according to claim 1, wherein said contact sleeve has an encircling free region which is encapsulated by casting in a sealing material.

10. The HV cable set according to claim 9, wherein said contact sleeve has a number of recesses formed therein and through said recesses, said sealing material extends.

11. The HV cable set according to claim 9, wherein said sealing material forms a housing shell which, on an outside, has an encircling groove formed therein for receiving a cable tie.

12. The HV cable set according to claim 1, wherein said contact sleeve has an interior space in which a tension relief device is disposed.

13. The HV cable set according to claim 1, further comprising a connection part, the HV cable set is connected by means of said connection part to an electrical HV component of a vehicle.

14. The HV cable set according to claim 7, wherein said common shield is connected to said contact sleeve by soldering or welding.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING

[0030] FIG. 1 is a diagrammatic, perspective view of a detail of an HV cable set;

[0031] FIG. 2 is a perspective view of the arrangement as per FIG. 1 without a housing shell;

[0032] FIG. 3 is an exploded, perspective view of the arrangement as per FIG. 2;

[0033] FIG. 4 is a sectional view of the arrangement as per FIG. 1; and

[0034] FIG. 5 is an illustration showing the HV cable set in an overall view.

DETAILED DESCRIPTION OF THE INVENTION

[0035] Referring now to the figures of the drawings in detail and first, particularly to FIG. 1 thereof, there is shown a detail of an HV cable set 2 in an oblique view. The HV cable set 2 has a number of cables 4, which in this case are three phases of a high-voltage connection. The cables 4 are formed in each case without separate shielding, which is to say without individual shielding, and the cables 4 are rather surrounded by a common shield 6. The latter is in this case formed as a braid composed of tin-plated copper wires. The cables 4 are in this case secured in a tension relief device 8, and run through a connection piece 10 which is for example a part of a connector housing (not illustrated in any more detail here). Furthermore, a sealing material 12 is provided, which in this case additionally forms a housing shell which encircles the tension relief device 8, the cables 4, the shield 6 and the connection piece 10. An encircling groove 14, which is of fully encircling form, is formed into said housing shell in a radial direction R, which encircling groove serves for receiving a cable connector (not illustrated in any more detail here).

[0036] FIG. 2 illustrates the arrangement from FIG. 1 without the sealing material 12. It is possible here to clearly see a contact sleeve 16 which is enclosed by the sealing material 12 and which is integrated in a longitudinal direction L into the connection piece 10. In the embodiment shown here, the connection piece 10 is also formed in the manner of a sleeve and has, in the longitudinal direction L, a front surface into which the contact sleeve 16 is inserted in the longitudinal direction L. Here, the arrangement composed of contact sleeve 16 and connection piece 10 is produced in particular by virtue of the contact sleeve 16 being encapsulated by casting, at the end side, in material for forming the connection piece 10. In the embodiment shown here, the contact sleeve 16 furthermore has a longitudinal slot 17. In an alternative which is not shown, the contact sleeve 16 is produced for example by deformation of a tubular section, and then has no longitudinal slot 17.

[0037] The construction is illustrated further by the exploded illustration in FIG. 3 and by the sectional illustration in FIG. 4. It can be seen that the contact sleeve 16 has an interior space 18 in which the tension relief device 8 is seated. The shield 6 is then pushed in the longitudinal direction L onto the contact sleeve 16, specifically in such a way that said contact sleeve is seated at the end side in the shield 6 and is surrounded by the latter. The contact sleeve 16 thus has a contact surface 20 which points outward in the radial direction R and which serves for producing an electrical connection to the shield 6. In particular, the shield is soldered or welded to the contact surface 20.

[0038] As is clear in particular from FIG. 4, there is formed on the contact sleeve 16 a free region 22 which is covered neither by the shield 6 nor by the connection piece 10 in the radial direction R. The free region 22 is however optimally covered by the sealing material of the housing shell 12, such that an ingress of moisture is prevented. In this way, contact corrosion between connection piece 10 and contact sleeve 16 at the edge of the free region 22 is also prevented.

[0039] It can also be clearly seen that the contact sleeve 16 has a length L1 in the longitudinal direction L, and is seated over approximately one third of the length L1 in the connection piece 10. In this way, between connection piece 10 and contact sleeve 16, there is formed a touching region 24 in which, in this case, owing to the production process, no air inclusions are present and an oxidation of the material of the connection piece 10 is avoided. In this way, in the touching region 24, particularly low contact resistance is realized, and contact corrosion, that is to say the formation of a local element, is efficiently prevented.

[0040] As shown for example in FIG. 3, a number of recesses 26 is formed into the contact sleeve 16 in the radial direction R, through which recesses the sealing material 12 ingress into the interior space 18 of the contact sleeve 16. This also clearly emerges from FIG. 4. In this way, it is in particular the case already during the production process that any error and moisture are displaced out of the interior of the arrangement, and thus the risk of contact corrosion as a result of an ingress of an electrolyte is eliminated.

[0041] FIG. 5 shows a complete view of the HV cable set 2. Here, it is possible to clearly see the three cables 4 surrounded by the shield 6. At the end side, the cables run into an HV component 30. Extending from the latter is the connection piece 10 on which the shield 6 and the contact sleeve 16 are mounted.

[0042] The following is a summary list of reference numerals and the corresponding structure used in the above description of the invention: [0043] 2 HV cable set [0044] 4 Cable [0045] 6 Shield [0046] 8 Tension relief means [0047] 10 Connection piece [0048] 12 Sealing material [0049] 14 Encircling groove [0050] 16 Contact sleeve [0051] 17 Longitudinal slot [0052] 18 Interior space [0053] 20 Contact surface [0054] 22 Free region [0055] 24 Touching region [0056] 26 Recess [0057] 30 HV component [0058] R Radial direction [0059] L Longitudinal direction [0060] L1 Length