Electric plug-in connector with improved environmental compatibility

Abstract

The present invention relates to an electric plug-in connector which has an improved environmental compatibility through the use of sustainable materials.

Description

[0001] Electrical connector with improved environmental compatibility

[0002] Description

[0003] The present invention relates to an electrical connector which has improved environmental compatibility through the use of sustainable materials.

[0004] State of the art

[0005] Electrical connectors typically comprise one or more plastic components. These include, for example, insulating bodies, locking mechanisms, protective covers, cable glands, and housings. Modular connectors allow the combination of a multitude of individual connector modules, which are usually combined in a housing via a retaining frame. The individual connector modules, as well as the housing and retaining frame, can be designed as plastic components.

[0006] In recent years, environmental compatibility and sustainability, particularly with regard to carbon footprint and recyclability, have become a focus of attention in the production of electrical connectors. One of the European Union's stated goals is to improve the recyclability of industrial products and achieve a 55% reduction in harmful greenhouse gases by 2030 compared to 1990 levels.

[0007] Typically, the production of plastic components for electrical connectors and connector modules uses materials that negatively impact the carbon footprint of the electrical connector and are non-recyclable. These include, for example, petroleum-based polymers (so-called synthetic polymers) and / or fillers that are not based on sustainable materials. Overall, this creates a major environmental disadvantage, as these products must be incinerated at the end of their life cycle, requiring high energy input and releasing environmentally harmful greenhouse gases.

[0008] It is well known that sustainable raw materials can be used to reduce the carbon footprint of an industrial product. For example, LIS2016 / 0237353 A1 describes flame-retardant block copolymers made from renewable raw materials, such as polylactide. The block copolymers described can be used in various industrial products. Electrical connectors are subject to very strict requirements, particularly with regard to low flammability. The block copolymers described in US2016 / 0237353 A1 achieve reduced flammability by incorporating a phosphorus-containing polymer.

[0009] Corresponding block copolymers based on polylactides currently do not show sufficient mechanical and thermal properties for use in electrical connectors.

[0010] In light of the above, there is a need to further develop an electrical connector that offers improved environmental compatibility. At the same time, the electrical connector should meet industrial requirements and be able to be manufactured cost-effectively.

[0011] It is therefore an object of the present invention to provide an electrical connector which is characterized by improved environmental compatibility.

[0012] The task is solved by an electrical connector that has at least one component made of a sustainable material.

[0013] A second subject of the present invention is also a component comprising at least one sustainable material.

[0014] A third object of the present invention is also the use of a sustainable material in a component for an electrical connector to improve the environmental compatibility of the electrical connector.

[0015] For a better understanding of the invention, the following explanations of the terminology used herein are considered useful. For the purposes of the invention:

[0016] - “Sustainable material” is a collective term for all materials based on natural or recycled raw materials. This includes, in particular, sustainable polymers which, within the meaning of the present invention, are not a direct product of exclusively petrochemical production. The term “sustainable material” also includes sustainable fillers which, through their use, can reduce the environmental compatibility of a product / manufacturer. Sustainable fillers are generally of natural origin or result from low-energy-intensive processes, recycling, treatment or reuse processes, or arise as waste products in industrial processes. - “a”, “an”, “an” as an article before a chemical compound class, e.g. before the word “polymer”, means that one or more compounds falling under this chemical compound class, e.g. different polymers, can be meant.In a preferred embodiment, this article refers to only a single compound;.

[0017] - "at least one", "at least one", "at least one" numerically "one or more". In a preferred embodiment, this term means numerically "one", "an", "an";

[0018] - "Contain," "comprise," and "include" indicate that, in addition to the components mentioned, further components may be present. These terms are meant inclusively and therefore also include "consist of." "Consist of" is meant conclusively and means that no further components may be present. In a preferred embodiment, the terms "contain," "comprise," and "include" mean the term "consist of."

[0019] For the purposes of the present invention, the term “electrical connector” also includes modular connectors in which at least two or more individual connector modules are combined with one another.

[0020] To improve the environmental compatibility of an electrical connector, in principle, every component of the electrical connector can contain a sustainable material. However, components that may be made of plastic (so-called plastic components) are preferably used to incorporate sustainable materials. These typically include one or more insulating bodies, the housing, protective covers, cable glands, and / or components of one or more locking mechanisms. If the electrical connector is modular, a retaining frame in the form of a plastic component can also be added.

[0021] According to the invention, at least one component of an electrical connector contains one or more sustainable materials; preferably, at least one plastic component contains at least one sustainable material. Considering all (plastic) components of an electrical connector, it is also possible for two or more (plastic) components to contain the same or different sustainable materials. With regard to improving the environmental compatibility of electrical connectors, it is generally advantageous if as many, preferably all, (plastic) components of an electrical connector contain one or more sustainable materials.

[0022] The term “plastic 1For the purposes of the present invention, "solid" refers to a solid that predominantly comprises a polymeric matrix containing one or more polymers. The proportion of the polymeric matrix in the plastic is preferably at least 70 wt.%, more preferably at least 80 wt.%, more preferably at least 90 wt.%, and even more preferably at least 95 wt. Further constituents of the plastic component can be, for example, organic and / or inorganic fillers that are added to the polymer matrix to adjust certain properties of the resulting plastic.

[0023] In one embodiment of the invention, the sustainable material comprises one or more sustainable organic fillers incorporated into a polymeric matrix. The group of sustainable fillers preferably includes flax fibers, cotton fibers, bamboo fibers, silk fibers, ground wood, plant stems, and / or shells. In a preferred embodiment of the invention, the aforementioned sustainable fillers are used in combination with at least one sustainable polymer, with the sustainable polymer particularly preferably being a thermoplastic. The term "sustainable polymer" refers to all polymers based on naturally occurring or recycled raw materials. Naturally occurring raw materials for producing a sustainable polymer can be derived from renewable raw materials, such as one or more natural oils.Such polymers are also referred to as renewable or bio-based polymers. The production of such bio-based or renewable polymers is known to those skilled in the art and will not be discussed further here.

[0024] In a particularly preferred embodiment of the invention, the bio-based polymer comprises at least one thermoplastic polyester produced from naturally occurring raw materials. The sustainable polymer is preferably a thermoplastic polyester selected from the group consisting of polylactides (polylactic acids, PLA), polyhydroxyalkanoates (PHA), and mixtures thereof.

[0025] It is also possible for the bio-based polymer, alone or in combination with the aforementioned bio-based polymers, to comprise at least one polyamide from sustainable sources. Castor oil, for example, can be used as a sustainable starting material for the production of sustainable polyamides. Polyamide 11 (PA11), polyamide 510 (PA510), and polyamide 1010 (PA1010) are particularly preferred, which are preferably used in combination with a sustainable filler.

[0026] The use of a sustainable organic filler also includes the use of recycled pressed paper and cellulose material. In this case, the solution is intended for needs where operating temperatures are low and flammability requirements are less restrictive. Pressed paper can be used in combination with a high-temperature-resistant coating or other material layer that protects the pressed paper material from electrical discharges and other undesirable events that could cause the connector to ignite.

[0027] In an alternative embodiment of the invention, the sustainable material comprises at least one elastomer based on naturally occurring or recycled raw materials. This includes, in particular, the use of natural rubber, which occurs naturally in more than 200 plant species. Natural rubber can be vulcanized and reinforced with fillers to reduce deformation under load and increase mechanical strength. In this context, the use of a bio-based EPDM (ethylene-propylene-diene rubber), for example, commercially available under the trade name Keltan eco EPDM from Arlanxeo, is particularly preferred. Sustainable elastomers (elastomers based on sustainable raw materials) such as styrene-butadiene rubber (SBR), c / s-polybutadiene rubber (BR), nitrile-butadiene rubber (NBR), isobutylene-isoprene rubber (NBR) and / or polyisoprene rubber (IR) can also be used.

[0028] In one embodiment, it is also possible to use high-performance polymers, such as polyphenylene sulfide (PPS), as a sustainable material within the meaning of the present invention if the polymer originates from a process or raw material that results in a product with improved environmental compatibility. This also includes, for example, polymers that are only partially based on bio-based raw materials. Partially bio-based polymers include, among others, bio-based polyurethanes (PUR), bio-based thermoplastic elastomers (TPE), or polytrimethylene terephthalate (PTT, a semi-crystalline polymer).

[0029] In a further alternative embodiment of the invention, it is also possible to use non-metallic inorganic materials as sustainable materials. These include, in particular, ceramics, glass, and hybrid materials. Hybrid material systems include the combination of metallic and ceramic materials and / or the combination of polymer-based and ceramic-filled materials. Here, the plastic component does not have to be manufactured by injection molding. Casting processes are typical for ceramic slurries. Inorganic materials include mud, clay, and terracotta. Although ceramics and other inorganic materials mentioned here are generally brittle and heavier than polymer-based materials, they offer very high thermal resistance, excellent insulation properties, and very high pressure resistance and could therefore be useful for specific applications.

[0030] In another alternative embodiment of the invention, the sustainable material comprises one or more inorganic fillers, which are used with the previously described sustainable polymers (bio-based and / or recycled). The addition of the inorganic filler has a positive effect on the mechanical properties and flammability of the final product, while a metallic filler can impart a new electromagnetic shielding function to the polymer. Ceramic fillers in the form of nanopowders and nanoparticles include NiO, BaTiOs, TiC, AlN, Al2O3, SiC, SisN4, Sr2Ce2TisOi6, zirconium silicate, wollastonite (CaSiOs), silicon dioxide (SiC>2), beryllium oxide (BeO), CeO2, boron nitride, and ZnO. Metallic fillers include shredded recycled wires, etc.All listed materials can be obtained from components whose service life has expired, so that these are sustainable materials within the meaning of the present invention.

[0031] In a further alternative embodiment of the invention, it is also conceivable that layered materials are used as sustainable materials. In this embodiment, the improved environmental compatibility of the electrical connector is achieved in that the layered material comprises at least two layers, wherein at least one layer (usually the inner layer) comprises a sustainable material. The second (outer) layer, which does not necessarily comprise a sustainable material, completely covers the inner layer. The outer layer compensates for deficiencies in the mechanical and electrical properties of the inner layer. The outer layer can be designed to improve impact resistance, hardness, corrosion resistance, etc. This makes it possible, for example, to achieve weight savings, which in turn have a positive effect on environmental compatibility.

[0032] In principle, it can be assumed that the greater the proportion of sustainable materials in the components of the electrical connector and thus in the electrical connector itself, the better this impact on the environmental compatibility of the electrical connector.

[0033] In one embodiment of the invention, the electrical connector comprises an insulating body comprising at least one sustainable material. In another embodiment of the invention, the electrical connector comprises a housing comprising at least one sustainable material.

[0034] In a further embodiment of the invention, the electrical connector comprises a protective cover which comprises at least one sustainable material.

[0035] In a further embodiment of the invention, the electrical connector comprises a locking mechanism which comprises at least one sustainable material.

[0036] In a preferred embodiment of the invention, the aforementioned embodiments can be combined with each other in any way with regard to the specification of the components of the electrical connector, so that the electrical connector comprises more than one component which contains one or more sustainable materials.

[0037] The production of plastic components for electrical connectors is typically carried out using injection molding. Injection molding offers the advantage of being simple and cost-effective. Other manufacturing methods include autoclave or resin injection processes for layering composite materials, manual lay-up techniques, casting processes, UV curing, or microwave curing. In cases where paper is used as a sustainable material, pulp injection molding is a technique that allows paper-based components to be produced from a combination of pulp water (paper) and starch. This process can be used to produce injection-molded cellulose-based components.The present invention also further relates to a component, preferably a plastic component, for an electrical connector containing one or more sustainable materials. The component is preferably an insulating body, a protective cover, a locking mechanism, a cable gland, or a housing of an electrical connector. With regard to the component according to the invention, all of the above statements apply equally. If the electrical connector is a modular connector, a retaining frame may also be present as a plastic component.

[0038] A further object of the present invention is also the use of at least one sustainable material in at least one component, in particular in a plastic component of an electrical connector, to improve the environmental compatibility of the electrical connector.

[0039] Preferably, the component is an insulating body, a protective cover, a locking mechanism, a cable gland and / or a housing of an electrical connector.

[0040] To achieve the greatest possible improvement in the environmental compatibility of the electrical connector, as many as possible, preferably all, components of the electrical connector, especially all plastic components, should contain one or more sustainable materials. The sustainable materials can be the same or different depending on the component's requirements.

[0041] With regard to the use according to the invention, all the above statements apply equally, as far as applicable.

Claims

Claims 1 . Electrical connector, characterized in that the electrical connector comprises at least one component which comprises one or more sustainable materials.

2. Electrical connector according to claim 1, characterized in that the component is a plastic component selected from the group consisting of insulating bodies, housings, locking mechanisms, cable glands and protective covers.

3. Electrical connector according to claim 1 or 2, characterized in that the electrical connector is a modular connector.

4. Electrical connector according to one of the preceding claims, characterized in that the sustainable material comprises one or more sustainable organic fillers.

5. Electrical connector according to claim 4, characterized in that the sustainable organic filler is selected from the group consisting of flax fibers, cotton fibers, bamboo fibers, silk fibers, ground wood and plant stems and / or shells.

6. Electrical connector according to one of claims 4 or 5, characterized in that the sustainable material additionally comprises at least one sustainable polymer.

7. Electrical connector according to one of claims 4 to 6, characterized in that the sustainable polymer is a bio-based and / or a recycled polymer.

8. Electrical connector according to one of claims 1 to 3, characterized in that the sustainable material is a sustainable elastomer.

9. Electrical connector according to claim 8, characterized in that the sustainable elastomer is a natural rubber.

10. Electrical connector according to one of claims 1 to 3, characterized in that the sustainable material is a non-metallic inorganic material selected from the group consisting of ceramic, glass and / or hybrid materials.

11. Electrical connector according to one of claims 1 to 3, characterized in that the sustainable material comprises at least one sustainable inorganic filler and at least one sustainable polymer.

12. Component for an electrical connector containing one or more sustainable materials.

13. Component according to claim 12, characterized in that the component is a plastic component selected from the group of insulating bodies, locking mechanisms, protective covers or the housing of an electrical connector.

14. Use of at least one sustainable material in at least one component of an electrical connector to improve the environmental performance of an electrical connector.

15. Use according to claim 14, characterized in that the component is a plastic component.

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