EP2192655B1 - Tight plug connection for high voltage cables in the automotive industry - Google Patents

Abstract

The connector has a plug or socket (6) comprising a metal-retainer bush (15) for a cable, where the connector is molded completely with a thermoplastic elastomer or pure thermoplastic or silicone. A sleeve (10) is divided into two portions in a longitudinal axis. The sleeve is made of aluminum-die casing unit, and has a tubular sleeve section (11) and a conically extended sleeve section. The sleeve is pressed on an isolation layer (2). The two portions are welded, soldered or glued in a sealed manner. A shielding network (3) of a cable strand is laid over the tubular sleeve section.

Description

This invention relates to a male or female connector for a male-female connection, for example, with floating contact, as used primarily in electrically powered vehicles, be it hybrid vehicles or pure electric vehicles. In such vehicles, currents must be able to flow at a voltage of 400 volts and higher and with currents of 150 A and higher in cables and the associated cable connections for feeding the electric motors. Therefore, these cables are called high-voltage cables or in the technical language High Voltage Cable or HVC. They are provided internationally with an orange isolation. As a cable for the power supply, those with a large strand cross-section are used to keep resistance losses low. The copper strands are enclosed by an insulation and the same is then in turn surrounded by a metallic protective braid, which again consists of an insulating layer. The high voltages make special shielding necessary so that other nearby electric devices are not disturbed by electric and magnetic fields. The protective braid is then bordered by a temperature-resistant orange cable insulation, for example made of a silicone, but other materials than cable insulation can be considered. This cable insulation can withstand temperatures of up to 200 ° C and higher.

At the cable ends, a corresponding plug or an associated socket is mounted to achieve a cable connection. And here it is technical problem is to ensure this connection to the plug or socket mechanical and electrical properly and to make sufficiently tight on the cable side and maintain this connection and the shield. These compounds are exposed to extreme loads in a vehicle. In vehicle operation, there are large temperature differences and large fluctuations in the humidity which clog these connections due to the effects of the weather. In addition, vehicles are sometimes sprayed with hot steam, and the compounds must therefore also withstand such hot steam and remain tight. Add to that the aging process. A connection, so the transition from the cable to the plug or from the cable to the socket should be perfect even after several years in relation to the mechanical and electrical connection, and also be perfectly tight.

The automotive industry has therefore issued standards that such compounds must meet. In order for a plug connection or socket connection, for example, to be exposed to a hot steam jet, it must comply with the DIN 40050 IP69K standard. Since September 2009, for example, the Volkswagen Group has to comply with the group standard VW 80302. To check compliance with the standard, air is blown from the cable end into the interior of the insulation and tested under water or with a differential pressure test to ensure that the connection remains tight. Of course, this test does not exactly imitate the stress of the connection in the installed vehicle, but the test is nonetheless practical and is therefore widely used.

The plug or the socket on the cable side has a receiving socket for the cable. The conventional plug connections and socket connections for high voltage cables of electric and hybrid vehicles have a receiving socket for the cable strand, and the plug-socket connection is encapsulated from the outside for sealing completely with a thermoplastic elastomer or a pure thermoplastic. The encapsulation takes place at a temperature of the injection molding material of about 160 to about 190 ° C. If now the plug connection after cooling the encapsulation is subjected to a compressed air test as described above by compressed air from the cable side to, for example, 1 bar through the inside of the cable insulation on the plug connection, this occurs at the front between the cable insulation and stranded wire from the cable and finally flows between the cable insulation and the just sprayed for sealing thermoplastic elastomer or a pure thermoplastic back to the outside. From the US 4 296 986 A is a plug or socket connection for a cable connection for high voltage cables of electric and hybrid vehicles known, with two-layer insulated cable strand and a Abschirmgeflecht between the two insulation layers. The plug or the socket on the cable side has a receiving socket for the cable.

The object of the present invention is, in the context of the prior art, to specify a plug connection for a cable connection for high-performance cables, wherein the cable strands have two layers of insulation layers, between which a shielding braid surrounds the inner insulation layer. The connection is intended to ensure better electromagnetic shielding between sockets and cables, while optimally electrical and mechanical connection of cable with plug or cable with socket. In this case, the plug connection must also withstand increased demands in terms of tightness on the cable side of the plug or the socket and in particular survive the above-mentioned compressed air test.

This object is achieved by a plug or socket connection for a cable connection for high voltage cables of electric and hybrid vehicles with double-layered cable strand with Abschirmgeflecht between the two insulating layers, the plug or the socket side cable has a receiving socket for the cable, and the entire Plug or socket connection for hermetic sealing of liquids completely encapsulated with a thermoplastic elastomer, or a pure thermoplastic, or with silicone in a spray temperature range of 160 ° C to about 190 ° C from the outside, characterized in that a in longitudinal axis in two parts split sleeve, for example, die-cast aluminum with first tubular sleeve portion and then conically widening sleeve portion with its tubular sleeve portion at the end of the cable strand whose first insulating layer is pressed aufschliessend on the same and the two parts welded together, soldered or glued, and that the Abschirmgeflecht the cable strand is slipped over the pressed tubular sleeve portion over the same.

Figur 1:

Eine gerade Buchsenverbindung mit dem zuführenden Hochspannungskabel;

Figur 2:

Die gerade Buchsenverbindung mit der Verbindung zum zuführenden Hochspannungskabel nach Figur 1 in einem Längsschnitt dargestellt;

Figur 3:

Das Detail X aus Figur 2, nämlich die Verbindung von Hülse und Kabellitze in vergrösserter Darstellung;

Figur 4:

Die gerade Buchse mit der Buchsenverbindung zum zuführenden Hochspannungskabel nach Figur 1 und 2 in perspektivischer Ansicht von schräg vorne gesehen dargestellt;

Figur 5:

Eine rechtwinklige Buchsenverbindung in einem Längsschnitt dargestellt;

Figur 6:

Die rechtwinklige Buchsenverbindung nach Figur 5 in perspektivischer Ansicht dargestellt.

In the figures, this plug or socket connection with the cable is shown with reference to several drawings and will be described in detail below.
It shows:

FIG. 1:

A straight socket connection with the supplying high voltage cable;

FIG. 2:

The straight socket connection with the connection to the supplying high voltage cable after FIG. 1 shown in a longitudinal section;

FIG. 3:

The detail X out FIG. 2 , namely the connection of sleeve and cable strand in an enlarged view;

FIG. 4:

The straight socket with the socket connection to the feeding high voltage cable after FIGS. 1 and 2 shown in perspective view obliquely seen from the front;

FIG. 5:

A right-angle socket connection is shown in a longitudinal section;

FIG. 6:

The right-angle socket connection FIG. 5 shown in perspective view.

The FIG. 1 shows such a plug or socket connection with socket 6 and supplying high voltage cable 1. The compound is suitable both for a connection of a high voltage cable to a plug as well as with a socket for such an associated connector. These two elements, ie plug and socket, are plugged together to create the cable connection. The connection from the cable to the plug on the one hand as well as the connection from the cable to the socket can be made identical. Therefore, the connection is shown and described here only on the example of a socket 6. The actual connection region is encapsulated with a skirt 7 of thermoplastic elastomer or of a pure thermoplastic or of silicone. This enclosure 7 is carried out at a temperature of the injection molding material of about 160 to about 190 ° C. In the front region of the socket 6, a handle 8 is placed with a textured surface, which is made of aluminum.

The FIG. 2 shows this socket 6 in a longitudinal section along the line AA of FIG. 1 so that their interior is visible. The high voltage cable 1 consists in the core of a copper strand 5, which is bordered by a first insulating layer 2 made of plastic. This insulating layer 2 is then enveloped by a metallic Abschirmgeflecht 3, and finally the Abschirmgeflecht 3 is in turn surrounded by a further, second insulating layer 4 made of plastic. The copper strand 5 is inserted with its freed from the outer insulation 4 and the Abschirmgeflecht 3 end portion 14 in a metal receiving socket 15 in order to achieve an electrical connection with the socket. The actual electrical socket 16 is then formed by a subsequent piece of metal. This electrical socket 16 is bordered by a plastic sleeve 20, wherein a sealing ring 22 between the sleeve 16 and the plastic sleeve 20 is inserted. For the mechanical connection of the high-voltage cable to the socket 6, a two-part sleeve 10, which encloses the connecting region with its two halves, is pressed around the end region of the high-voltage cable 1. The end region of the high-voltage cable 1 is first freed from the outer insulation layer 4 in preparation for this connection. Then the exposed end of the Abschirmgeflechtes 3 slipped back over the outer insulation 4 of the high voltage cable 1 and thereafter, the two sleeve halves are welded together under compression of the enclosed cable end portion, soldered or glued. The cable end portion is freed at this point from the outer insulation layer 4 and the cable strand 5 is only surrounded by the first insulating layer 2. For the welding of the two sleeve halves, a laser welding along the cut surfaces 23 of the two sleeve halves is used. On the inside, the sleeve halves are provided with a flexible insulation sleeve 17. This takes over the insulation between the conductor and the shield. After welding, the braided screen 3 is slipped over the tubular portion 11 of the sleeve 10, so that it surrounds this section 11 all around. This causes only a slight expansion of the braided shield 3, which proves to be advantageous. The braided shield 3 is then wrapped at this point with a metal band 18, which is then secured by means of a resistance welding. This ensures a seamless shielding up to the front edge of the conically widening metallic sleeve 10. This has over the previous method, where the Abschirmgeflecht is attached to the large diameter at the connector housing has the advantage that the Abschirmgeflecht does not need to be expanded and thus unfolds a better shielding effect. At its front end, the sleeve 10 with its edge 12 a complementarily shaped edge 13 of the female mount behind engages placed on the same, so that a secure mechanical connection of the socket 6 is achieved with the high voltage cable 1. To ensure the tightness of the connection is first a press ring 9 made of metal, which surrounds the outer insulation 4 of the high voltage cable 1 in the end and ensures that no moisture or gas between the insulation 2,4 and the copper strand 5 can penetrate. Outside, the pressing 9 forms a groove. The entire connection area is afterwards encapsulated with a thermoplastic elastomer or a pure thermoplastic from the outside sealingly, wherein also the pressing ring and its groove is overmolded, resulting in an excellent tightness. In the front region of the socket 6, a handle 8 is placed with a textured surface, which is made of hard plastic.

The FIG. 3 shows the detail X FIG. 2 , namely the connection of sleeve 10 and cable strand 5 in an enlarged view. The sleeve 10 is provided on its inside with two grooves 19, so that it is non-slip on the first insulating layer 2 of the cable strand 5 can be pressed. These grooves 19 cause a corresponding deformation of the insulation layer 2 of the cable strand 5 and an increasingly clamped on train deadlock. On its inside, the sleeve 10 is provided with an insulating sleeve 17 made of rubber-elastic plastic. Starting from the end of the outer insulation layer 4 of the cable or the cable strand 5, the Abschirmgeflecht 3 is slipped over the entire tubular portion 11 of the sleeve 10.

The FIG. 4 shows this socket 6 with their connection to the supplying high voltage cable 1 after FIGS. 1 and 2 shown in perspective view obliquely seen from the front. First of all, one recognizes the electrical socket 16 made of metal. It is comprised of a plastic grip sleeve 8. This is followed by the encapsulation 7 of a thermoplastic elastomer or of a pure thermoplastic.

The FIG. 5 shows an identical connection from the high voltage cable 1 to the socket 6, wherein this is designed here as a rectangular socket connection. The actual connection, namely the tubular sleeve portion 11, which surrounds the cable strand 5 with the first insulating layer 2, after which the Schirmgeftecht 3 is slipped over this section 11, is carried out exactly the same as in the example of a straight socket as in the FIGS. 1, 2 and 4 is shown. The only difference in the embodiment shown here is that the sleeve 6 and thus also the connecting sleeve 10 forms a right angle and is therefore shaped accordingly.

The FIG. 6 shows such a rectangular socket connection after FIG. 5 in perspective view. In the same way, bushes with a curvature of, for example, 150 or 120 or degrees can be built. In these variants, the welding of the sleeve has the advantage that the sleeve in each Any angle of rotation can be attached to the socket or plug housing. This is necessary because the plug and the electrical socket 16 is coded at the front, so are provided with cams, and so can only be plugged together in a certain position, although they are round. It is at the socket connection as in FIG. 6 shown possible that in the illustrated position of the electrical socket 16 and the handle 8, this electrical socket 16 is mated with a located in the same rotational position plug, but not when the socket 16 opposite the plug occupies a different rotational position. The cable must therefore lead away from the socket 16 exactly as shown. However, with the same position of socket 16 and associated plug, it may be necessary that the cable be led away in a different direction for geometric reasons, not to the right rear as shown here, but for example to the right front or left rear, etc. This is possible and can be made according to the customer, so always the same sleeve for the connection can be used, only the rotational position of the electrical socket 16 to the sleeve changes accordingly.

Claims (10)

1. Male-, respectively, female-connector for a cable connection for high tension cable of electrical and hybrid vehicles with an isolated cable strand (5) in two layers and a shield netting (3) between the two isolation's layers (2,4); wherein the male-, respectively, the female-connector presents a reception female connector (15) for the cable (1) and wherein, the entire male-, respectively, female-connector is completely molded from the outside with a thermoplastic elastomer or with a pure thermoplastic or with silicon molding at a temperature comprised between 160°C up to about 190°C, characterized in that, a barrel (10) which is separated in two parts in direction of the longitudinal axis and constituted of aluminum pressure molding is at first, pressed with the tubular barrel section (11) and with the said adjacent barrel section extending conically with its tubular barrel section (11) located at the end of the cable strand (5) the first isolation's layer (2) of which being pressed on the said cable strand encircling it and characterized in that, the two parts are welded together in a sealing manner, and in that the shield netting (3) of the cable strand (5) is put over the tubular barrel section from the pressed tubular barrel section (11).
2. Male-, respectively, female-connector for a cable connection for high tension cable of electrical and hybrid vehicles according to claim 1, characterized in that the shield netting (3) is wrapped with a metal band (18) around the tubular barrel section (11) and the said shield netting is closed by means of an electric resistance welding.
3. Male-, respectively, female-connector for a cable connection for high tension cable of electrical and hybrid vehicles according to any of the preceding claims, characterized in that the barrel (10) is equipped with an isolation sleeve (17) on its inner side.
4. Male-, respectively, female-connector for a cable connection for high tension cable of electrical and hybrid vehicles according to any of the preceding claims, characterized in that, the two barrel halves are welded by means of a laser welding or soldered or stuck together on their cut surfaces (23).
5. Male-, respectively, female-connector for a cable connection for high tension cable of electrical and hybrid vehicles according to any of the preceding claims, characterized in that the inner side of the tubular section (11) of the barrel (10) is equipped with grooves.
6. Male-, respectively, female-connector for a cable connection for high tension cable of electrical and hybrid vehicles according to any of the preceding claims, characterized in that the end area of the cable (1) is encircled with a pressure ring (9) presenting outwards a circumferential groove.
7. Male-, respectively, female-connector for a cable connection for high tension cable of electrical and hybrid vehicles according to any of the preceding claims, characterized in that the lining (7) constituted of thermoplastic elastomer or pure thermoplastic comprises the entire connection, e.g., from the wire (1) to beyond the connection of the edge (12) of the cone formed by the barrel (10).
8. Male-, respectively, female-connector for a cable connection for high tension cable of electrical and hybrid vehicles according to any of the preceding claims, characterized in that, the connection forms a right angle with a rectangular barrel (10).
9. Male-, respectively, female-connector for a cable connection for high tension cable of electrical and hybrid vehicles according to claim 1 to 7, characterized in that, the connection forms an angle of 120° with a barrel (10) comprising an angle of 120°.
10. Male-, respectively, female-connector for a cable connection for high tension cable of electrical and hybrid vehicles according to claim 1 to 7, characterized in that, the connection forms an angle of 150° with a barrel (10) comprising an angle of 150°.

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