Electrical connection assembly

Abstract

An electrical connection assembly comprising: a connector body (370) with a passage (376) formed therein; and an electrical connection (10,310,500,502,504), comprising: a contact section (12,312) with a contact arm (22,24,26,28); and a spring arrangement (30) with a spring arm (32, 24, 26, 28) engaging with the contact arm (22, 24, 26, 28); and a unidirectional mounting device that prevents the electrical connection (10, 310) from being inserted into the passage (376) in an incorrect orientation, wherein the unidirectional mounting device is defined by an asymmetric opening (378) of the passage (376) of the connector body (370), wherein the electrical connection (10, 310) has several sides (14, 16, 18, 20), and wherein a first side differs in its dimensions from the other sides such that the electrical connection (10, 310) can only be inserted into the passage (376) in one orientation. characterized by the fact that the passage (376) has several slots (382,384,386,388) corresponding to the several sides (14,16,18,20) of the electrical connection (10,310), that a first slot differs in dimension in relation to the other slots (382,384,386,388), and that the unidirectional mounting device is defined by the insertion of the first side within the first slot.

Description

GENERAL STATE OF THE ART

[0001] The present invention relates generally to electrical connectors for electrical connection assemblies, such as those used in electric and hybrid vehicles. Electrical connection assemblies typically have a housing made of plastic or another non-conductive material. One or more electrical plug or socket connectors are arranged within the housing. The connectors with the socket terminals are connected to connectors with push-in pins, so that the coupled pins and the connections between them provide electrical communication. The pins can be a rod, a cylinder, or a plate that slides into the connector to establish contact.Electrical socket connectors are typically formed from a stamped metal blank designed to include one or more compliant arms that engage the outer edges of the pin to provide electrical communication between them. It is often important to ensure that the electrical connectors are properly positioned within the housing so that any platform or wire connector of the connector is correctly oriented.

[0002] DE 198 35 020 A1 discloses a socket contact with a base spring surrounded by a rectangular overspring. The overspring has overspring tongues that act on contact springs. The overspring has a polarizing element to ensure unidirectional insertion of the socket contact into a contact chamber of a contact carrier.

[0003] DE 695 15 582 T2 discloses an electrical terminal block with a contact body having a connecting section. The contact body has polarization extensions to ensure that the terminal block can be inserted into a connector housing cavity in two different orientations.

[0004] US 5,893,780 A discloses an electrical connector with a sleeve-shaped body that engages contact strips via spring strips. The sleeve-shaped body has projections to allow insertion in two different orientations. EP 0 774 801 A2 discloses an electrical connector contact with an inner body and an outer body. The outer body has a recess in its upper wall and another in its lower wall, which interact with projections arranged on opposite sides in a connector housing in two possible orientations. BRIEF DESCRIPTION OF THE INVENTION

[0005] The invention relates to an electrical connection assembly comprising a connector body with through-holes formed therein and an electrical connection. The electrical connection includes a contact section with a contact arm and a spring assembly with a spring arm engaging with the contact arm. The electrical connection assembly further includes a unidirectional mounting device that prevents the electrical connection from being inserted into the through-hole in the wrong orientation.

[0006] Various aspects of the present invention will become apparent to the person skilled in the art from the following detailed description of the preferred embodiments upon reading in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS Fig. Figure 1 is a schematic view of an electrical charging assembly. Fig. Figure 2 is a perspective view of a first embodiment of an electrical connection. Fig. Figure 3 is a perspective view of the electrical connection of Fig. 1, where the contact section is shown partially broken away. Fig. Figure 4 is a perspective view of a second embodiment of an electrical connection, showing the contact section partially broken away. Fig. Figure 5 is a perspective view of a third embodiment of an electrical connection. Fig. Figure 6 is a perspective view of the electrical connection of Fig. 5, where the contact section is shown partially broken away. Fig. Figure 7 is a perspective view of a fourth embodiment of an electrical connection, in which the contact section is shown partially broken away. Fig. Figure 8 is a perspective view of a fifth embodiment of an electrical connection. Fig. Figure 9 is a perspective view of the electrical connection of Fig. 8, shown before insertion into a connector body. Fig. Figure 10 is a perspective view of the electrical connection of Fig. 8, shown before an attempted insertion into a connector body, but with incorrect orientation. Fig. Figure 11 is an enlarged perspective view of the electrical connection and connector body of Fig. 10, which represents the attempted incorrect assembly. Fig. Figure 12 is a perspective view of a sixth embodiment of an electrical connection. Fig. Figure 13 is a perspective view of a seventh embodiment of an electrical connection. Fig. Figure 14 is a perspective view of an eighth embodiment of an electrical connection. Fig. Figure 15 is a perspective view of a ninth embodiment of an electrical connection. DETAILED DESCRIPTION OF THE PREFERRED EXECUTION FORM

[0007] Now, with reference to the drawings, in Fig. Figure 1 shows a power charging cable assembly generally displayed at 200. As described below, various aspects regarding the Fig. The electrical connections shown and described in sections 2 to 12 are used in various components of the charging cable assembly. It should also be understood that assembly 200 is merely an example of a suitable system that can use the electrical connections as described herein, and that the electrical connections can be used in any other suitable electrical connector assembly.

[0008] The power charging cable assembly 200 can be used for electric vehicles or hybrid vehicles (e.g., plug-in hybrid vehicles) that are charged by a remote power supply 202. For example, the power supply 202 can be installed and mounted within a garage belonging to an apartment or can be part of a charging station to supply electrical power for charging the batteries of the electric or hybrid vehicle. The batteries within the vehicle can receive and store electrical energy from the external power supply 202. The assembly 200 includes a charging cable, generally shown at 204. The charging cable 204 is a flexible power cable with a vehicle connector 206 at one end and a plug 208 at the other. The vehicle connector 206 is coupled to a vehicle inlet 210 to provide electrical communication between the charging cable 204 and the vehicle.The vehicle inlet 210 communicates electrically with the batteries and other electrical components of the vehicle. The connector 208 is coupled to a socket 212 of the power supply 202 to provide electrical communication between the charging cable 204 and the power supply 202. One or more electrical connections, as described herein, may be located in the vehicle connector 206, the connector 208, the vehicle inlet 210, and / or the socket 212 to facilitate electrical connection between the respective coupling components. The electrical connections are configured to couple with a connector, such as an electrical pin, which can be repeatedly inserted and removed from engagement with the electrical connection.

[0009] The charging cable 204 can also include an internal control box 214, which is connected between the ends of the charging cable 204. The control box 214 can accommodate various electrical components for controlling and regulating different aspects of the electrical current or voltage propagating through the charging cable 204. For example, the control box 214 can include features such as ground fault protection and monitoring, charger circuit interrupt devices, and indicator lights.

[0010] Fig. Figure 2 shows a perspective view of an electrical terminal, generally shown at 10. The terminal 10 contains a contact section 12 with a contact section base 13 having sides 14, 16, 18, 20, forming a generally rectangular structure. The contact section 12 further contains four pairs of contact arms 22, 24, 26, 28, each extending from one of the respective sides 14, 16, 18, 20. As described in more detail below, the pairs of contact arms 22, 24, 26, 28 are arranged to receive a coupling electrical component, such as a round or square pin 66, such that each pair of contact arms 22, 24, 26, 28 contacts the coupling electrical component.

[0011] The terminal 10 also includes a spring assembly 30, which comprises four spring arms 32, 34, 36, 38. Each of the spring arms 32, 34, 36, 38 has a respective spring body 40, 42, 44, 46, which is arranged along a central section of a respective pair of the contact arms 22, 24, 26, 28. Each of the spring arms 32, 34, 36, 38 also contains a respective spring head 50, 52, 54, 56 in contact with a respective pair of contact arms 22, 24, 26, 28 near a distal end 58 of the contact section 12. The spring heads 50, 52, 54, 56 exert a force on the respective pair of contact arms 22, 24, 26, 28 in a direction that extends towards an opposite pair of contact arms - for example, the spring head 56 exerts a force on the contact arms 28 in a direction towards the opposite pair of contact arms 24; analogously, the contact head 34 exerts a force on the contact arms 24 in a direction towards the opposite pair of contact arms 28.As explained in more detail below, the configuration of the spring arrangement and, in particular, the contact of the spring heads with the respective pairs of contact arms increases the holding force exerted on a coupling electrical component, such as a pin.

[0012] Although the in Fig. While the embodiment shown in Figure 2 is a four-sided, generally rectangular structure, embodiments of the present invention may have fewer than or more than four sides to create a different type of generally polygonal structure. For example, a three-sided structure may have a generally triangular cross-section, and a five-sided structure may have a generally pentagonal cross-section. In such a case, the spring would not exert a force on a number of contact arms in one direction toward an opposite pair of contact arms, since the above examples have an odd number of sides. However, regardless of the number of sides, the springs will exert a force on the respective contact arms in one direction toward a central axis of the terminal, such as the one shown in Figure 2. Fig. 2 shown axis 59.

[0013] A terminal such as terminal 10 can be effectively used in high-current applications where a soft copper conductor might lose its holding power in the presence of the potentially large heat associated with some high-current applications. To help avoid these problems, some prior art electrical terminals use a copper alloy, which may have better high-temperature properties; however, this is often at the expense of conductivity, which may be better with purer copper or a softer copper alloy. In the case of the Fig. In the electrical connection shown in Figure 2, the contact section 12 can be made of a relatively soft copper material such as C151, while the spring assembly 30 can be made of a relatively stiff and strong steel such as stainless steel 301.

[0014] Although the tensile stress exerted on the contact arms 22, 24, 26, 28 by the spring heads 50, 52, 54, 56 would normally be adequate to hold the components in their relative orientations, the in Fig. 2. In the embodiment shown, an additional feature is incorporated to further ensure that the relative orientation is maintained. As shown in Fig. As shown in Figure 2, each of the spring bodies 40, 42, 44, 46 has at least one section arranged between a respective pair of contact arms 22, 24, 26, 28, which helps to ensure that the spring heads 50, 52, 54, 56 are in the proper position and exert the force reasonably evenly between each of the respective contact arms in the pairs of contact arms 22, 24, 26, 28.

[0015] As also in Fig. As shown in Figure 2, the contact section 12 includes a platform 60 configured for connection to a wire or other electrical component, for example by ultrasonic welding. The platform 60 extends from a proximal end 61 of the contact section 12. The platform 60 can have any suitable shape for coupling to a wire or other electrical component and can extend from any of the sides 14, 16, 18, 20 (or a combination of sides 14, 16, 18, 20) of the contact section 12.

[0016] Fig. Figure 3 shows a fragmentary view of the in Fig. 1 shown electrical connection 10. The spring assembly 30 includes, in addition to the spring arms and respective spring bodies and spring heads, a spring base 62 from which each of the spring arms 32, 34, 36, 38 extends (see also Fig. 1) extends outwards. In this embodiment, the spring base 62 and the spring arms 32, 34, 36, 38 consist of a single piece of material. The spring base 62 includes a through-passage 64 for receiving a coupling electrical component, such as the round pin 66. The through-passage 64 is dimensioned to receive the pin 66 with a desired frictional fit, ensuring sufficient electrical contact while still allowing the pin 66 to be retracted from the through-passage 64 in the spring base 62. This configuration helps to support the pin 66 and allows the connection 10 to be coupled with much longer pins than would otherwise be possible. That is, if the only contact between the pin 66 and the electrical connection 10 is on the pair of contact arms 22, 24, 26, 28 (see Fig. 2) If this occurred, an undesirable degree of relative movement could occur between the pin 66 and the connector 10. Having a spring base 62 configured with the bushing 64 provides the additional support required to reduce this relative movement, thus allowing the connector 10 to be coupled with longer pins such as the pin 66.

[0017] In Fig. Figure 4 shows a second embodiment of an electrical connection, generally shown at 10', with a contact section 12'. The dash symbol (') is used to indicate features similar to those shown in the other figures. A spring assembly 68 includes a spring base 70 with a through-hole 72 passing through it, but in this embodiment, the through-hole includes a neck 73, which can be formed, for example, by a drawing process. This configuration provides additional support for the pin 66' and can further strengthen the spring assembly 68. The configuration of the through-hole 72 and the neck 73 provides the ability to accommodate a longer engagement between the pin 66 and the spring base 62 and allows the pin 66 to pass through the back plane of the spring base 62. Also shown in Fig. Figure 4 shows that the spring base 70 is arranged within the contact section base 12, and the spring arms 32, 34, 36, 38 extend through the contact section base 12 and along an outside of each pair of contact arms (see also Fig. 2) A similar configuration is in Fig. 3 shown with connection 10'.

[0018] Fig. Figure 5 shows a perspective view of a third embodiment of an electrical connector, generally shown at 74. The connector 74 comprises a contact section 76 with a contact section base 78 and four sides 80, 82, 84, 86, forming a generally rectangular structure. The contact section 78 further comprises four contact arms 88, 90, 92, 94. As above regarding the in Fig. As described in the embodiment shown in 2, the Fig. The terminal 74 shown in Figure 5 can have fewer than or more than four sides, each having its own contact arms extending from it. The terminal 74 also includes a spring assembly 96, which has four spring arms 98, 100, 102, 104. Each of the spring arms 98, 100, 102, 104 consists of two individual elongated links that spread over one of the respective contact arms 88, 90, 92, 94, and which terminates in a spring head 106, 108, 110, 112.

[0019] The spring heads 106, 108, 110, 112 each contact one of the contact arms 88, 90, 92, 94 near a distal end 114 of the terminal 74 and exert a force in one direction towards an opposite contact arm 88, 90, 92, 94. More generally, each of the spring heads 106, 108, 110, 112 exerts a force on one of the contact arms 88, 90, 92, 94 in one direction towards a central axis 115 of the terminal 74. As in the Fig. In connection 10 shown, connection 74 contains a platform 116 which is configured to connect to a wire or other electrical component, for example by ultrasonic welding.

[0020] In Fig. 6 is a fragmentary view of the in Fig. 3 shown electrical connection 74. In addition to the spring arms and respective spring heads (in Fig. (not designated 6) the spring assembly 96 contains a spring base 118 from which each of the spring arms 98, 100, 102, 104 extends (see also Fig. 5) extends outwards. In this embodiment, the spring base 118 and the spring arms 98, 100, 102, 104 consist of a single piece of metal. The spring base 118 includes a through-hole 120 for receiving a coupling electrical component, such as the round pin 122. The through-hole 120 is dimensioned to receive the pin 122 with a desired frictional fit, ensuring sufficient electrical contact while still allowing the pin 122 to retract from the through-hole 120 in the spring base. This configuration helps to support the pin 122 and allows the terminal 74 to couple with much longer pins than would otherwise be possible.

[0021] In Fig. Figure 7 shows a fourth embodiment of an electrical connection, generally indicated at 74', with a contact section 76'. A spring assembly 124 includes a spring base 126 with a through-hole 128 passing through it. In this embodiment, the through-hole 128 includes a neck 130, which can be formed, for example, by a drawing process. This configuration provides additional support for the pin 122' and can further strengthen the spring assembly 124. The configuration of the through-hole 128 and the neck 130 provides the ability to accommodate a longer engagement between the pin 122' and the spring base 126 and allows the pin 122' to pass through the back plane of the spring base 126.

[0022] In Fig. Figure 8 shows a fifth embodiment of an electrical connector, generally indicated at 310. The connector 310 is similar to the one in Figure 8. Fig. 2 and Fig. The terminal 310 is shown in Figure 3, with one of the differences being a shorter length to provide a low-profile design and to improve packaging options. The terminal 310 includes a contact section 312 with a contact section base 313 having sides 314, 316, 318, and 320, forming a general rectangular structure. The contact section 312 further includes four pairs of contact arms 322, 324, 326, and 328, each extending from one of the respective sides 314, 316, 318, and 320. The pairs of contact arms 322, 324, 326, and 328 are designed to receive a coupling electrical component, such as a round or square pin, so that each pair of contact arms 322, 324, 326, and 328 contacts the coupling electrical component.

[0023] The connection 310 also includes an external spring assembly 330, which comprises four spring arms 332, 334, 336, 338. Each of the spring arms 332, 334, 336, 338 has a respective spring body 340, 342, 344, 346, which is arranged along a central section of a respective pair of the contact arms 322, 324, 326, 328. Each of the spring arms 332, 334, 336, 338 also includes a respective spring head 350, 352, 354, 356 in contact with a respective pair of the contact arms 322, 324, 326, 328 near a distal end 358 of the contact section 312.The spring heads 350, 352, 354, 356 exert a force on the respective pair of contact arms 322, 324, 326, 328 in a direction towards the opposite pair of contact arms – for example, spring head 356 exerts a force on contact arms 328 in a direction towards the opposite pair of contact arms 324; similarly, contact head 334 exerts a force on contact arms 324 in a direction towards the opposite pair of contact arms 328. The configuration of the spring assembly, and in particular the contact of the spring heads with the respective pairs of contact arms, increases the holding force exerted on a coupling electrical component such as a pin.

[0024] Also in Fig. As shown in Figure 8, the contact section 312 includes a platform 360 configured for connection to a wire or other component, for example by ultrasonic welding. The platform 360 extends from a proximal end 361 of the contact section 312. The platform 360 can have any suitable shape for coupling to a wire or other electrical component and can extend from any of the sides 314, 316, 318, 320 (or combinations of sides 314, 316, 318, 320) of the contact section 312.

[0025] The 310 connector can include a polarization or unidirectional mounting device, allowing it to be installed in a proper or desired orientation within a connector body. For example, as shown in Fig. Figure 9 shows a connector body 370 containing the terminal 310 when properly installed. It should be understood that although the connector body 370 is shown configured to receive a single terminal 310, it can be configured to receive any number of terminals 310. The connector body 370 can, for example, be a section of the vehicle connector 206, the plug 208, the vehicle inlet 210, and / or the socket 212. The connector body 370 includes a first and second end 372 and 374. The connector body can be made of plastic or another non-conductive material. The connector body 370 includes a passage 376 formed through it. The passage 376 defines a first opening 378 at the first end 372 of the connector body 370 and a second opening 380 at the second end.To install connector 310, connector 310 is inserted into the first opening 378, as shown in . Fig. 9 shown. However, the shape of the first opening 378 is asymmetrical, so that the connection 310 fits into the passage 376 in a predetermined or desired orientation. In the Fig. In the embodiment of the connector body 370 shown in Figure 9, the passage 376 contains four grooves 382, ​​384, 386 and 388 formed therein. The groove 388 has a width W G , which is larger than the latitudes W G' the other three grooves 382, ​​384 and 386. The spring body 346 of the spring arm 338 has a section with a width Ws that is larger than the widths W S' the other three spring bodies 340, 342 and 344 of the spring arms 332, 334 and 336. The width W G The groove 388 preferably has the same size as, or is slightly larger than, the width Ws of the spring body 346. As in Fig. 10 and Fig. As shown in Figure 11, attempting to install the connector 310 incorrectly, for example by aligning the spring arm 388 with the groove 386 (or the grooves 382 and 384), creates an obstruction, preventing the connector 310 from being inserted into the passage 378 of the connector body 370. Specifically, the width Ws of the spring body 346 of the spring arm 338 is greater than the width W G' the groove 386.

[0026] In Fig. Figure 12 shows a sixth embodiment of an electrical connection, generally indicated at 400. Connection 400 is similar to connections 74 and 74' of the Fig. 5 to 7. One of the differences is that terminal 400 has a polarization or unidirectional mounting device by modifying the shape of a contact section 402, thereby making it asymmetrical. In the case of the Fig. In the embodiment shown in Figure 12, the contact section 402 has a recess 404 formed in a corner between two adjacent sides 406 and 408. The other three corners 410 of the contact section do not have a corresponding recess. A connector body not shown may have corresponding features such that the terminal 400 can only be inserted in one of the four orientations. For example, a single groove formed in the passage of the connector body may be shaped to accommodate only the recess 404. Thus, it should be understood that the polarity or one-way feature may be formed and used in any suitable section of the electrical terminal and / or the connector body and is not limited to the specific examples shown herein.

[0027] Another difference between the electrical terminal 400 and terminals 74 and 74' is the shape and configuration of a platform 420. Instead of a relatively flat plate, the platform 420 includes corner sections 422 and side sections 424 extending from a base section 426. The configuration of the platform 420 can accommodate wires, connectors, and other electrical components (not shown) that communicate electrically with the contact section 402 of the terminal 400.

[0028] In the Fig. Figures 13 to 14 show seventh, eighth, and ninth embodiments of electrical terminals 500, 502, and 504, respectively. Terminals 500, 502, and 504 have differently shaped platforms which, compared to the rearward-extending platforms, are Fig.Figures 2 to 12 show connections extending in other directions. It should be noted that these connections have a low-profile configuration, making them shorter in length compared to connections 10 and 74. It is understood that the electrical connections can be configured with a platform or platforms of any suitable shape and can extend from any desired side and corner of the contact section.

[0029] It is understood that the terminal 310 and the connector body 380 may be configured in any suitable coupling manner provided by the polarizing or unidirectional mounting device.

[0030] The principle and operation of the present invention have been explained in its preferred embodiments. However, it should be understood that the present invention can be practiced in ways other than those specifically explained and described without deviating from its underlying concept or scope of protection.

Claims

[1] An electrical connection assembly comprising: a connector body (370) having a passage (376) formed therein; and an electrical connection (10,310,500,502,504) comprising: a contact section (12,312) with a contact arm (22,24,26,28); and a spring arrangement (30) having a spring arm (32,24,26,28) engaging the contact arm (22,24,26,28); and a unidirectional mounting device that prevents the electrical terminal (10,310) from being inserted into the passage (376) in an incorrect orientation, the unidirectional mounting device being defined by an asymmetric opening (378) of the passage (376) of the connector body (370), the electrical terminal (10,310) having a plurality of sides (14,16,18,20), and a first side differing in dimension from the other sides such that the electrical terminal (10,310) can only be inserted into the passage (376) in one orientation, characterized by , that the passage (376) has a plurality of grooves (382,384,386,388) corresponding to the plurality of sides (14,16,18,20) of the electrical terminal (10,310), that a first groove differs in dimension with respect to the other grooves (382,384,386,388), and that the unidirectional mounting device is defined by inserting the first side within the first groove. [2] The terminal assembly of claim 1, wherein the electrical terminal (10,310) comprises a plurality of spring arms (32,34,36,38,98,100,102,104,332,334,336,338), and wherein the first side is defined by a width of a first spring arm having a different width than the other spring arms. [3] An electrical connection assembly comprising: a connector body (370) having a passage (376) formed therein; and an electrical connection (400) comprising: a contact section (402) with a contact arm (22, 24, 26, 28); and a spring arrangement (30) with a contact arm (22,24,26,28) in engaging spring arm (32,24,26,28); and a unidirectional mounting device which prevents the electrical connection (400) from being inserted into the passage (376) in an incorrect orientation, characterized by , that the unidirectional mounting device is defined by an asymmetric shape of the contact portion (402), and that the contact portion (402) has a recess (404) formed therein. [4] The terminal assembly of claim 3, wherein the contact portion (402) has a plurality of sides (406,408), and wherein the recess (404) is formed in only one of the sides (406,408) of the contact portion (402). [5] The terminal assembly of claim 4, wherein the contact portion (402) is formed from a metallic blank. [6] The terminal assembly of claim 5, wherein the contact portion (402) includes a platform (420) extending from one side thereof. [7] The terminal assembly of claim 6, wherein the platform (420) is flat. [8] The connector assembly of claim 6, wherein the platform (420) has side portions (424) extending from a flat base portion (426). [9] The terminal assembly of claim 6, wherein the platform extends in a direction perpendicular to an axis of insertion of the terminal (500,502,504) into the passageway.

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