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EP2192655B1 - Connecteur étanche pour câbles à haute tension dans l'industrie automobile - Google Patents

Connecteur étanche pour câbles à haute tension dans l'industrie automobile Download PDF

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Publication number
EP2192655B1
EP2192655B1 EP09176421A EP09176421A EP2192655B1 EP 2192655 B1 EP2192655 B1 EP 2192655B1 EP 09176421 A EP09176421 A EP 09176421A EP 09176421 A EP09176421 A EP 09176421A EP 2192655 B1 EP2192655 B1 EP 2192655B1
Authority
EP
European Patent Office
Prior art keywords
cable
connection
connector
female
male
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Not-in-force
Application number
EP09176421A
Other languages
German (de)
English (en)
Other versions
EP2192655A2 (fr
EP2192655A3 (fr
Inventor
Patrik Scheiber
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Satrotec AG
Original Assignee
Satrotec AG
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Satrotec AG filed Critical Satrotec AG
Publication of EP2192655A2 publication Critical patent/EP2192655A2/fr
Publication of EP2192655A3 publication Critical patent/EP2192655A3/fr
Application granted granted Critical
Publication of EP2192655B1 publication Critical patent/EP2192655B1/fr
Not-in-force legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/46—Bases; Cases
    • H01R13/502—Bases; Cases composed of different pieces
    • H01R13/504—Bases; Cases composed of different pieces different pieces being moulded, cemented, welded, e.g. ultrasonic, or swaged together
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/46—Bases; Cases
    • H01R13/52—Dustproof, splashproof, drip-proof, waterproof, or flameproof cases
    • H01R13/5205—Sealing means between cable and housing, e.g. grommet
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/58—Means for relieving strain on wire connection, e.g. cord grip, for avoiding loosening of connections between wires and terminals within a coupling device terminating a cable
    • H01R13/5845—Means for relieving strain on wire connection, e.g. cord grip, for avoiding loosening of connections between wires and terminals within a coupling device terminating a cable the strain relief being achieved by molding parts around cable and connections
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R2201/00—Connectors or connections adapted for particular applications
    • H01R2201/26—Connectors or connections adapted for particular applications for vehicles
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/02—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for soldered or welded connections
    • H01R43/0214—Resistance welding

Definitions

  • 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.
  • 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.
  • a corresponding plug or an associated socket is mounted to achieve a cable connection.
  • 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 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.
  • 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.
  • 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 Ablegeflecht 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.
  • 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.
  • a plug or socket connection for a cable connection for high voltage cables of electric and hybrid vehicles with double-layered cable strand with Ablegeflecht 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 Ablegeflecht the cable strand is slipped over the pressed tubular sleeve portion
  • 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.
  • 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 Ablegeflecht 3, and finally the Ablegeflecht 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 Ablegeflecht 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.
  • 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 Ablegeflmüs 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.
  • a laser welding along the cut surfaces 23 of the two sleeve halves is used.
  • the sleeve halves are provided with a flexible insulation sleeve 17. This takes over the insulation between the conductor and the shield.
  • 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 Ablegeflecht is attached to the large diameter at the connector housing has the advantage that the Ablegeflecht does not need to be expanded and thus unfolds a better shielding effect.
  • 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.
  • 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.
  • a handle 8 is placed with a textured surface, which is made of hard plastic.
  • 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.
  • 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 Ablegeflecht 3 is slipped over the entire tubular portion 11 of the sleeve 10.
  • 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.
  • 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.
  • 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.
  • FIG. 6 shows such a rectangular socket connection after FIG. 5 in perspective view.
  • bushes with a curvature of, for example, 150 or 120 or degrees can be built.
  • 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.

Landscapes

  • Connector Housings Or Holding Contact Members (AREA)
  • Details Of Connecting Devices For Male And Female Coupling (AREA)
  • Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)

Claims (10)

  1. Connexion mâle, respectivement femelle pour une liaison par câble destinée aux câbles à haute tension de véhicules électriques ou hybrides au moyen d'un toron de câble (5) isolé en deux couches, avec un treillis de blindage (3) entre les deux couches d'isolation (2,4); où la connexion male, respectivement la connexion femelle (6) présente, du côté du câble, une prise femelle (15) pour le câble (1); l'ensemble prise mâle, respectivement, femelle est totalement recouvert par projection de l'extérieur par un élastomère thermoplastique ou un thermoplaste pur, ou du silicone à une température de projection comprise entre 160°C et 190°C pour rendre l'ensemble prise mâle - femelle complètement hermétique aux liquides, caractérisé en ce qu'une enveloppe (10) coupée en deux parties en direction de l'axe longitudinal et constituée d'un moulage sous pression en aluminium, est pressé avec la section d'enveloppe tubulaire (11) et comportant de façon adjacente à la cette section (10) et avec la section adjacente d'enveloppe (11) tubulaire qui s'élargit en forme de cône avec sa section d'enveloppe (11) au bout du toron de câble (5) dont la première couche d'isolation (2) est pressée sur ladite section tubulaire en l'entourant, et les deux parties sont soudées entre elles de manière étanche , et en ce que le treillis de blindage (3) du toron de câble (5) est retourné à partir de la section d'enveloppe tubulaire (11) pressée sur ladite section.
  2. Connexion mâle respectivement femelle pour une liaison par câble destinée aux câbles à haute tension de véhicules électriques ou hybrides selon la revendication 1, caractérisée en ce que le treillis de blindage (3) situé sur la section d'enveloppe (11) tubulaire (11) est entourée d'une bande métallique (18) et ledit treillis de blindage est fermé au moyen d'un soudage électrique par résistance.
  3. Connexion mâle respectivement femelle pour une liaison par câble destinée aux câbles à haute tension de véhicules électriques ou hybrides selon une des revendications précédentes, caractérisée en ce que l'enveloppe (11) est équipée sur son côté intérieur, d'une enveloppe isolante (11).
  4. Connexion mâle respectivement femelle pour une liaison par câble destinée aux câbles à haute tension de véhicules électriques ou hybrides selon une des revendications précédentes, caractérisée en ce que les deux moitiés de l'enveloppe sont soudées ou brasées ou collées sur leurs surfaces de coupe (23) par un soudage au laser.
  5. Connexion mâle respectivement femelle pour une liaison par câble destinée aux câbles à haute tension de véhicules électriques ou hybrides selon une des revendications précédentes, caractérisée en ce que le côté intérieur de la section d'enveloppe (11) tubulaire est pourvu de rainures (19).
  6. Connexion mâle respectivement femelle pour une liaison par câble destinée aux câbles à haute tension de véhicules électriques ou hybrides selon une des revendications précédentes, caractérisée en ce que la zone terminale du câble (1) est entourée d'un anneau de serrage (9) qui présente, à l'extérieur, une rainure circonférentielle.
  7. Connexion mâle respectivement femelle pour une liaison par câble destinée aux câbles à haute tension de véhicules électriques ou hybrides selon une des revendications précédentes, caractérisée en ce que la gaine (7) réalisée en élastomère thermoplastique ou un thermoplaste pur, entoure toute la liaison, c'est-à-dire, à partir du câble (1) jusqu'à la connexion du bord (12) du cône formé par l'enveloppe (10).
  8. Connexion mâle respectivement femelle pour une liaison par câble destinée aux câbles à haute tension de véhicules électriques ou hybrides selon une des revendications précédentes, caractérisée en ce que la liaison forme un angle droit avec une enveloppe (10) rectangulaire.
  9. Connexion mâle respectivement femelle pour une liaison par câble destinée aux câbles à haute tension de véhicules électriques ou hybrides selon une des revendications 1 à 7, caractérisée en ce que la liaison forme un angle de 120° avec une enveloppe (10) qui comprend un angle de 120°.
  10. Connexion mâle respectivement femelle pour une liaison par câble destinée aux câbles à haute tension de véhicules électriques ou hybrides selon une des revendications 1 à 7, caractérisée en ce que la liaison forme un angle de 150° avec une enveloppe (10) qui comprend un angle de 150°.
EP09176421A 2008-12-01 2009-11-19 Connecteur étanche pour câbles à haute tension dans l'industrie automobile Not-in-force EP2192655B1 (fr)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
CH01874/08A CH700065A2 (de) 2008-12-01 2008-12-01 Dichte Stecker- oder Buchsenverbindung für Hochspannungskabel im Automobilbau.

Publications (3)

Publication Number Publication Date
EP2192655A2 EP2192655A2 (fr) 2010-06-02
EP2192655A3 EP2192655A3 (fr) 2011-01-26
EP2192655B1 true EP2192655B1 (fr) 2012-01-25

Family

ID=41718979

Family Applications (1)

Application Number Title Priority Date Filing Date
EP09176421A Not-in-force EP2192655B1 (fr) 2008-12-01 2009-11-19 Connecteur étanche pour câbles à haute tension dans l'industrie automobile

Country Status (3)

Country Link
EP (1) EP2192655B1 (fr)
AT (1) ATE543234T1 (fr)
CH (1) CH700065A2 (fr)

Families Citing this family (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102012202368B4 (de) * 2012-02-16 2023-05-17 Bayerische Motoren Werke Aktiengesellschaft Ladevorrichtung
KR101519274B1 (ko) 2013-12-20 2015-05-11 현대자동차주식회사 케이블 파손이 방지되는 커넥터
CN104538787B (zh) * 2015-01-15 2016-11-23 江苏赛洋机电科技有限公司 电缆连接器
WO2020030259A1 (fr) * 2018-08-08 2020-02-13 Hirschmann Automotive Gmbh Système d'étanchéité
CN109411972A (zh) * 2018-11-29 2019-03-01 河南亿元密封科技有限公司 一种一体连接氮氧传感器线束及其生产加工方法

Family Cites Families (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4296986A (en) * 1979-06-18 1981-10-27 Amp Incorporated High voltage hermetically sealed connector
US4408822A (en) * 1980-09-22 1983-10-11 Delta Electronic Manufacturing Corp. Coaxial connectors
DE102006049703C5 (de) * 2006-10-18 2014-07-17 Erich Jaeger Gmbh & Co. Kg Steckverbinder
EP2112721A1 (fr) * 2008-04-23 2009-10-28 Satrotec AG Connecteur étanche haute tension pour une utilisation automobile

Also Published As

Publication number Publication date
EP2192655A2 (fr) 2010-06-02
CH700065A2 (de) 2010-06-15
EP2192655A3 (fr) 2011-01-26
ATE543234T1 (de) 2012-02-15

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