Electrical Connector, Connector Assembly and Charging Robot for Conductive Charging System

Abstract

The object of the present invention is to improve the mating process and the lifetime of a charging system. The above object is achieved by an electrical connector (1) configured to mate with a mating connector (10) along a mating direction (14) and comprising at least two contact elements (3), each contact element having a contact surface (5), wherein each contact surface (5) is at least partially inclined with respect to the mating direction (14), and wherein at least two contact elements (3) are spaced apart from each other along a circumferential direction (12) with respect to the mating direction (14). Thus, the inclination of the contact surfaces (5) prevents the sliding of the contact surfaces (5) on the corresponding contact surfaces (11) of the mating connector (10). As a result, the amount of wear occurring during the mating process is reduced, and the required mating force is decreased.

Description

Technical Field

[0001] The present invention relates to an electrical connector, and more particularly, to an electrical connector for a charging system, in particular for a conductive charging system for an electric vehicle battery, accumulator, etc. Further, the present invention relates to a connector assembly and a charging robot including such an electrical connector. Background Art

[0002] In the field of electric vehicles, it is required that the charging system of the battery works with high efficiency throughout its service life and at the same time maintains its function. Charging systems operating according to the induction principle (i.e., energy transfer by electromagnetic induction between a source-side module and a load-side module) usually exhibit high energy losses and occupy a relatively large space. This is particularly disadvantageous for large-scale charging systems such as electric vehicle batteries, etc.

[0003] In a charging system where energy transfer is carried out by a current flowing directly between a source-side conductor and a load-side conductor (i.e., a conductive charging system), sufficient contact force is required between the corresponding conductors to achieve efficient energy transfer. The contact force is usually exerted by spring-like electrical contact elements forming the corresponding conductors. As a result, a high mating force is required during the mating process. In addition, the contact surfaces of the conductors slide and scrape against each other during the mating process, so there is a risk of wear and damage to the contact surfaces, which are usually coated with a conductive layer to reduce the contact resistance between the conductors. Damage to the contact surfaces leads to an increase in the electrical contact resistance and a decrease in the efficiency of the charging system.

[0004] Technical Problem to be Solved

[0005] The object of the present invention is to alleviate at least one of the above difficulties, thereby improving the mating process and / or the life of the charging system. Summary of the Invention

[0006] The above object is achieved by providing an electrical connector, such as an electrical connector for a conductive charging system for an electric vehicle battery, accumulator, etc., having a transmission capacity greater than 15 kW, preferably kW, configured to mate with a mating connector along a mating direction and including at least two, preferably identical and rigid contact elements, each contact element having a conductive contact surface, wherein each contact surface is at least partially inclined relative to the mating direction, preferably has a slope, and wherein at least two contact elements are spaced apart from each other along the circumferential direction relative to the mating direction. In particular, each contact surface may have at least one surface normal vector that includes a first vector component pointing in the mating direction and a second vector component perpendicular to the mating direction.

[0007] The above solution is advantageous because the inclination of the contact surface prevents sliding of the contact surface on the corresponding contact surface of the mating connector. In other words, the contact surface of the electrical connector can be in electrical contact with the corresponding contact surface of the mating connector only by abutment. Accordingly, the amount of wear occurring during the mating process is reduced and the required mating force is lowered.

[0008] By providing at least two contact elements that are separated from each other, the electrical connector can be used to conduct alternating current, preferably alternating current of about 40 A, for example between 10 A and 100 A. Additionally, at least two contact elements having their inclined contact surfaces can be configured to achieve a self-aligning function, as will be described further below.

[0009] The above solution can be further improved by adding one or more of the following optional features. Each of the following optional features is advantageous in itself and can be combined independently with any other optional feature.

[0010] According to a first embodiment, the electrical connector can include three contact elements, for example, for conducting three-phase current. Additionally, the three contact elements can provide three mechanical abutment points, which is advantageous for the stability of the electrical connector because the three mechanical abutment points precisely define a plane for a stable position (i.e., three-point stability).

[0011] Optionally and depending on the required electrical energy transmission, the electrical connector can also include more than three contact elements, preferably arranged in a circular pattern and having the same radius.

[0012] According to another embodiment, at least two contact elements can be separate structures and at least one gap can be formed between the at least two contact elements. More precisely, the at least two contact elements can be detachable structures, independent, self-supporting, and / or free-standing. If the electrical connector includes more than two contact elements, all of the contact elements can form gaps in pairs. By means of the gaps, the required clearance distance and creepage distance can be maintained.

[0013] According to another aspect of the invention, the electrical connector can include a substrate, preferably one of a circular, rectangular, oval, and polygonal disk-shaped substrate, wherein at least two contact elements can extend through the substrate along the mating direction. In particular, each contact element can penetrate the substrate and be rigidly held by the substrate. This is particularly advantageous because the substrate can serve as a means for attaching the contact elements, thereby preventing loss of the contact elements. The substrate can be made of an electrically insulating material, preferably resin, in order to serve as electrical insulation between the at least two contact elements.

[0014] Alternatively, at least one of the at least two contact elements may be attached to the substrate via a joint (e.g., a hinge joint) so as to be pivotable about a pivot axis extending perpendicular to the mating direction. This embodiment allows for compensation of misalignment between the contact surfaces of the at least two contact elements and the corresponding contact surfaces of the mating connector within the range of motion of the joint, thereby preventing jamming and poor contact.

[0015] Each contact element may include a contact portion and a termination portion, where the contact portion includes a contact surface and protrudes from the substrate in the mating direction. The termination portion may penetrate the substrate against the mating direction, e.g., through a slit that extends from an outer edge of the substrate towards an opposite edge of the substrate. The termination portion may be used to connect an internal cable or wire of the electrical connector to the corresponding contact element, e.g., by clamping, soldering, welding, or similar bonding methods. Additionally or alternatively, the termination portion may be used to attach the corresponding contact element to the aforementioned joint.

[0016] Furthermore, the electrical connector may include a connector housing made of an electrically insulating material (preferably a resin), where the connector housing may at least partially surround the at least two contact elements and / or the internal cable or wires of the electrical connector. The connector housing may be a connector shell or a connector housing fixedly attached to the substrate. In particular, the housing wall of the connector housing may extend along the outer periphery of the substrate and protrude in the mating direction. Thus, the connector housing can protect the electrical connector from external chemical, mechanical, or other harmful effects, such as water, dirt, or dust.

[0017] Alternatively, the connector housing may be a spring-loaded and movably attached connector shell or connector housing to the substrate. In this embodiment, the connector housing may move from a position that protects the at least two contact elements during the non-mating state to a position that does not cover the at least two contact elements during the mating state. In other words, before or during the mating process, the connector housing may retract against the mating direction.

[0018] Optionally, the substrate may include at least one receptacle to which the at least two contact elements are attached. Preferably, the at least two contact elements are rigidly attached to the at least one receptacle and fixedly held in their respective inclined positions. The at least one receptacle mechanically supports the corresponding contact elements and thus increases the overall stability.

[0019] In yet another possible embodiment, each contact element may be disposed on a separate receptacle, preferably an individual receptacle. This embodiment is advantageous because it represents a material-saving design of the electrical connector, thereby reducing the weight. More precisely, the receptacle material is concentrated and limited only to the positions necessary to provide mechanical support for the corresponding contact elements.

[0020] Each receptacle can protrude from the substrate in the mating direction to form a base shape or a column shape. Preferably, the receptacle can be formed monolithically from the substrate to reduce the number of components. Additionally, at least two contact elements can be stamped or pressed plate-like contact elements that are bent around the respective receptacle, where the receptacle has an inclined mounting surface that is parallel to the contact surface of the respective contact element, and where the contact element at least partially covers the mounting surface. Thus, the mounting surface can provide mechanical support for the respective contact element to abut against and support it.

[0021] According to another embodiment, the contact surfaces of at least two contact elements face outward (preferably inclined outward) or inward (preferably inclined inward) relative to the central plane of the substrate, where the center of the substrate is the centroid, the center of gravity, or the intersection of two or more symmetry axes of the substrate. Optionally, the central axis of the substrate passing through the center of the substrate can extend parallel to the mating direction, and the contact surfaces of at least two contact elements can face the central axis inclinedly or face away from the central axis inclinedly. More precisely, the contact surface can have at least one surface normal vector that includes a first vector component pointing in the mating direction and a second vector component pointing towards or away from the center and / or perpendicular to the central axis in the mating direction.

[0022] In this embodiment, at least two contact elements can be arranged such that the respective contact surfaces are part of the surface of a polyhedron, for example, a truncated pyramid, or a body of revolution about the central axis, for example, a frustum of a cone that widens or tapers in the mating direction. To this end, each contact surface can include at least one flat portion that is tangent to a surface of revolution about the central axis (such as a cone, a paraboloid of revolution, or a hemisphere). Alternatively, each contact surface of at least two contact elements can include at least one curved (preferably arcuate) portion that is part of a surface of revolution about the central axis, such as a cone, a paraboloid of revolution, or a hemisphere. More precisely, the contact surfaces of at least two contact elements can be distributed equiangularly and / or equidistantly in a circular arrangement, and each can extend along a section of the substrate in the circumferential direction relative to the center and / or the central axis.

[0023] This configuration is advantageous for applications where the mating connector includes complementary-configured contact surfaces (i.e., the contact surfaces are part of the surface of a polyhedron, for example, a truncated pyramid, or a body of revolution about the central axis, such as a frustum of a cone that widens or tapers in the mating direction, respectively). The respective contact surfaces can contact only by adjacency while also providing a self-aligning function. In other words, the geometric arrangement of the contact surfaces can be used to convert the relative movement between the electrical connector and the mating connector from translational movement in the mating direction to translational movement perpendicular to the mating direction. This results in translational movement towards the central axis. Thus, the alignment of the electrical connector and the mating connector, especially the alignment of the corresponding contact surfaces, can be facilitated.

[0024] Additionally or alternatively, in embodiments where the electrical connector includes a connector housing, the self-aligning function can be achieved by using the housing walls. In particular, the housing walls can have chamfered outer edges that taper in the mating direction. The mating connector can include a mating housing having a socket opening for receiving the electrical connector, where the shape of the socket opening is complementary to the connector housing, i.e., the socket opening has chamfered inner edges that widen in the mating direction. The conversion of the relative movement described above can be similarly effected by means of the chamfered edges.

[0025] According to a possible embodiment, the shapes of the housing walls and the socket opening can include behavior-shaping features for preventing the electrical connector from mating with the mating connector in the wrong position. More precisely, the housing walls and the socket opening can form a key-lock pair that can only be inserted into each other at predetermined discrete positions. This embodiment is particularly advantageous in applications where the electrical connector and the mating connector are manually mated.

[0026] According to another aspect of the invention, at least two contact elements have the same height relative to the mating direction. In particular, at least two contact elements are located at the same level relative to the mating direction, thereby allowing the corresponding contact surfaces to simultaneously abut against the corresponding contact surfaces of the mating connector during the mating process.

[0027] According to yet another aspect of the invention, each contact surface of at least two contact elements can have at least one convex protrusion, such as a ball protrusion or a pit. At least one convex protrusion can be formed during the manufacture of the contact element, for example, by a pressing or forging process, and represents a method of defining an electrical contact point.

[0028] Optionally, each contact surface of at least two contact elements can have a plurality of convex protrusions, and all the vertices of the plurality of convex protrusions are arranged on the surface of one of a common polyhedron and a solid of revolution. Thus, a plurality of points for electrical contact are defined, resulting in a larger cross-sectional area available for current.

[0029] In another possible embodiment, the electrical connector can further include a part of a coupler, where the coupler is a combination of one or both of a magnetic coupler and a mechanical coupler, as will be described below.

[0030] In particular, the electrical connector can include one of the active parts of a magnetic coupler, such as an electromagnet, and a passive part of the magnetic coupler, such as a mating ferromagnetic element, preferably concentrically attached to the center of a substrate, to attract the mating connector. The magnetic force of the magnetic coupler can be used to generate the necessary contact force between the corresponding contact elements of the electrical connector and the mating connector, while simultaneously assisting the alignment between the corresponding contact surfaces due to the predetermined orientation of the magnetic force that occurs.

[0031] Additionally or alternatively, the electrical connector may include a mechanical locking device for a mechanical coupler, the mechanical locking device being configured to engage with a complementary locking device of a mechanical connector on a mating connector in a mechanically interlocking connection. This embodiment is advantageous for applications that require additional contact force or where specifications regarding the weight and / or cost of the electrical connector do not allow the use of a magnetic coupler.

[0032] Further, the electrical connector may include at least one, preferably spring-loaded, contact pin that is movable, e.g., retractable against the mating direction, and has a conductive end portion facing the mating direction. At least one contact pin may be a spring pin and serve as an auxiliary contact that, during the mating process, abuts against the mating connector before the contact surfaces of at least two contact elements, thereby signaling proximity to the mating connector. By providing a spring-loaded contact pin, the spring-loaded contact pin can act as a damper for absorbing any mechanical shock that would otherwise damage at least two contact elements.

[0033] According to one embodiment, the electrical connector may include at least two contact pins, wherein at least one contact pin is connected to the neutral line of the electrical connector and at least one additional contact pin is connected to the ground line of the electrical connector, thereby serving as the neutral contact and the ground contact of the electrical connector, respectively. In particular, at least two contact pins may be arranged in a circular space between the center of the substrate and the connection circumference of the contact surfaces, the connection circumference being a circular line that passes through the innermost or outermost points of each contact surface or any other different geometric points of each contact surface.

[0034] In an embodiment including at least three contact elements and a magnetic coupler, at least two contact pins may be arranged in the space between the magnetic coupler and the at least three contact elements. In such an arrangement, the above-described three-point stability is not affected by the contact pins and is thus maintained.

[0035] Additionally or alternatively, the electrical connector may include at least one contact pad having a conductive end face facing the mating direction. At least one contact pad may be arranged mirror-image to a corresponding contact pin of the mating connector and is configured to abut against an end portion of the corresponding contact pin. In particular, the end face of the contact pad may be circular or arcuate, especially arcuate and extending in the circumferential direction to bridge certain misalignments within the extent of the contact pad, e.g., rotational misalignment relative to the central axis in the circumferential direction.

[0036] Preferably, the electrical connector may include at least two contact pads, wherein at least one contact pad is connected to the neutral line of the electrical connector, and at least one additional contact pad is connected to the ground line of the electrical connector. This embodiment is advantageous for applications with strict specifications regarding the weight of the electrical connector, since the weight of the contact pads is generally less than that of equivalent contact pins, while serving similarly as the neutral contact and the ground contact of the electrical connector, respectively.

[0037] The object mentioned at the beginning can also be achieved by a connector assembly, which includes an electrical connector according to one of the above embodiments, wherein the contact surfaces of at least two contact elements face outward, and includes a mating connector according to one of the above embodiments, wherein the contact surfaces of at least two contact elements face inward, and all contact points between the contact surface of the electrical connector and the contact surface of the mating connector are arranged on the surface of one of the polyhedrons, such as a truncated pyramid, or a body of revolution about a central axis, such as a frustum of a cone, respectively.

[0038] Such a connector assembly is advantageous because the corresponding contact surfaces can be in electrical contact only by adjacency, and there is no relative sliding between the corresponding contact surfaces. This results in a lower mating force and reduces scratching on the corresponding contact surfaces, thus facilitating the mating process and extending the service life of the charging system.

[0039] According to a possible embodiment of the above connector assembly, only one of the connectors may include convex protrusions on the corresponding contact surfaces, while the other connector has flat, plane and / or planar contact surfaces. Thus, the electrical contact points can be precisely defined.

[0040] According to another embodiment, the electrical connector may have one of the active parts of a magnetic coupler, for example, an electromagnet, and a passive part of the magnetic coupler, for example, a mating ferromagnetic element, while the mating connector has the corresponding other part. Thus, attraction can be established between the electrical connector and the mating connector.

[0041] Optionally, one of the connectors is the ground side connector of a conductive charging system and the other connector is the vehicle side connector of the conductive charging system. In this embodiment, the present invention can be used in conductive charging systems for electric vehicle batteries, accumulators, etc.

[0042] The above object can also be achieved by a charging robot, which includes a robotic arm, such as a 3-, 4- or 5-axis robotic arm, and an electrical connector according to one of the above embodiments, wherein the electrical connector is a ground-side connector mounted on the end portion of the robotic arm, and the robotic arm is configured to automatically move and mate the electrical connector with a vehicle-side connector. Thus, the mating process can be further facilitated by automation. For this purpose, the charging robot can further include sensors, preferably non-contact sensors, such as cameras and / or distance sensors, which are configured to provide measurement values to the control system of the charging robot to guide the movement of the robotic arm. Description of the Drawings

[0043] Hereinafter, embodiments of the present invention will be described with reference to the drawings. The illustrated and described embodiments are for illustrative purposes only. Combinations of features shown in the embodiments can be changed according to the foregoing description. For example, features not shown in the embodiments but described above can be added if the technical effects associated with the features are beneficial for a particular application. Vice versa, features shown as part of the embodiments above can be omitted if the technical effects associated with the features are not required in a particular application.

[0044] In the drawings, elements that correspond to each other in terms of function and / or structure have been provided with the same reference numerals.

[0045] In the drawings:

[0046] Figure 1 A schematic diagram of a perspective view of an electrical connector according to a possible embodiment of the present disclosure is shown;

[0047] Figure 2 A schematic diagram of a perspective view of an electrical connector according to another possible embodiment of the present disclosure is shown;

[0048] Figure 3 Shown is an electrical connector according to the Figure 1 embodiment shown in perspective view mated with a mating connector;

[0049] Figure 4 Shown is an electrical connector according to the Figure 3 embodiment shown in side view mated with a mating connector;

[0050] Figure 5 A schematic diagram of a perspective view of a connector assembly according to a possible embodiment of the present invention is shown; and

[0051] Figure 6 A schematic diagram of a side view of an electrical connector according to another possible embodiment of the present disclosure is shown.

[0052] Reference Figures 1 to 6The exemplary embodiments shown are used to explain the structure of possible embodiments of the electrical connector 1 and the connector assembly 2 according to the present invention. Detailed Description

[0053] Figure 1 A perspective view of an electrical connector 1 for a conductive charging system for an electric vehicle battery (not shown) according to an exemplary embodiment of the present invention is shown. The electrical connector 1 can be configured to mate with a mating connector 10 (see Figure 3 ) in a mating direction 14. To this end, the electrical connector 1 can include at least two, preferably identical and rigid, contact elements 3, each of which has a conductive contact surface 5. According to the illustrated embodiment, the at least two contact elements 3 have the same height 16 and are located at the same level 18 with respect to the mating direction 14 (see Figure 4 ).

[0054] Each contact surface 5 is at least partially inclined with respect to the mating direction 14, preferably angled. It can be seen that each contact surface 5 has at least one surface normal vector 6, which includes a first vector component 7 pointing in the mating direction 14 and a second vector component 8 perpendicular to the mating direction 14.

[0055] In addition, the electrical connector 1 can include a substrate 26. In the Figure 1 exemplary embodiment, a circular, disc-shaped substrate 26 is shown. Alternatively, the substrate 26 can have one of a rectangular, oval, and polygonal shape.

[0056] As Figure 1 and Figure 2 shown, the at least two contact elements 3 can extend through the substrate 26 in the mating direction 14, penetrate the substrate 26, and be rigidly held by the substrate 26. In particular, each contact element 3 can include a contact portion 28 and a termination portion 30. The contact portion 28 includes the contact surface 5 and protrudes from the substrate 26 in the mating direction 14. The termination portion 30 can penetrate the substrate 26 against the mating direction 14 through a slit 32 that extends from the outer edge 34 of the substrate 26 toward the opposite edge 36 of the substrate 26.

[0057] The substrate 26 can include at least one receptacle 38 to which the at least two contact elements 3 are attached. Preferably, the at least two contact elements 3 are rigidly attached to the at least one receptacle 38 so as to be fixedly held in their respective inclined positions.

[0058] In Figure 1 and Figure 2In the illustrated embodiment, the electrical connector 1 includes three contact elements 3a, 3b, 3c which are spaced apart from each other in the circumferential direction 12 relative to the mating direction 14. The three contact elements 3a, 3b, 3c can be separate, preferably self - contained, and can form gaps 40 in pairs. Additionally, the three contact elements 3a, 3b, 3c can provide three mechanical abutment points 42 for corresponding contact elements 4, 4a, 4b, 4c of the mating connector 10 (see Figure 3 ).

[0059] In Figure 1 , the contact surfaces 5a, 5b, 5c of the three contact elements 3a, 3b, 3c slope outwards relative to the center 44 of the substrate 26, where the center 44 of the substrate 26 is the center of gravity of the substrate 26. The three contact elements 3a, 3b, 3c can further deviate from the central axis 46 of the substrate 26, pass through the center 44 of the substrate 26 and extend parallel to the mating direction. Generally speaking, the contact surfaces 5a, 5b, 5c can each have at least one surface normal vector 6a, 6b, 6c which includes a first vector component 7a, 7b, 7c pointing in the mating direction 14 and a second vector component 8a, 8b, 8c perpendicular to the mating direction 14 and directed away from the center 44 and / or the central axis 46.

[0060] In particular, the contact surfaces 5a, 5b, 5c can be part of the outer surface 48 of a frustum - shaped pyramid 52 which tapers in the mating direction 14. To this end, each contact surface 5a, 5b, 5c can include at least one flat portion 54 as shown in Figure 1 . Alternatively, each contact surface 5a, 5b, 5c can include at least one curved (preferably arcuate) portion which is part of a surface rotated about the central axis 46, such as a cone, a paraboloid of revolution or a hemisphere. Additionally, the contact surfaces 5a, 5b, 5c can be distributed equi - proportionally and / or equidistantly in a circular arrangement, and each can extend along a section of the substrate 26 in the circumferential direction relative to the center 44 or the central axis 46.

[0061] It should be understood that, depending on the required electrical energy transmission, the electrical connector 1 can also include more than three contact elements 3. In this case, the plurality of contact elements 3 can be arranged around the center 44 of the substrate 26 in a circular arrangement and have the same radius. Additionally, the contact surfaces 5 can be arranged as part of the surface of any kind of polyhedron which widens or tapers in the mating direction 14, or alternatively, as part of the surface of any kind of body which widens or tapers in the mating direction 14 and is rotated about the central axis 46 of the substrate 26.

[0062] In Figure 2In this case, the contact surfaces 5a, 5b, 5c of the three contact elements 3a, 3b, 3c are inclined inwardly with respect to the center 44. Therefore, the contact surfaces 5a, 5b, 5c can be part of the inner surface 50 of a frustum-shaped pyramid 52 that widens in the mating direction 14.

[0063] In addition, in Figure 1 and Figure 2 In the illustrated embodiment, each contact element 3a, 3b, 3c is located on a separate individual seat 38 that protrudes along the mating direction 14. Each seat 38 can be monolithically formed from the substrate 26 into a pedestal-shaped block 56 having a mounting surface 58, where the mounting surface 58 is inclined with respect to the mating direction 14.

[0064] The contact elements 3a, 3b, 3c can be plate-shaped contact elements 3 that are bent around the respective seats 38 and at least partially cover the mounting surface 58. Preferably, the contact elements 3a, 3b, 3c are bent such that each contact surface 5a, 5b, 5c is parallel to the respective mounting surface 58. Thus, the mounting surface 58 can provide mechanical support 60 for the respective contact elements 3a, 3b, 3c to abut against and support them.

[0065] Referring again to Figure 1 , each contact surface 5a, 5b, 5c can have at least one convex protrusion 9, such as a ball protrusion 64 or a pit 66. In Figure 1 In the illustrated embodiment, each contact surface 5a, 5b, 5c has three convex protrusions 9. Depending on the required current-carrying capacity, each contact surface 5a, 5b, 5c can also have more than three convex protrusions 9. Preferably, all the vertices 68 of the plurality of convex protrusions 9 are arranged on the surface of one of the common polyhedra and solids of revolution.

[0066] In addition, the electrical connector 1 can include at least one, preferably spring-loaded, contact pin 70 that is movable, for example, can be retracted against the mating direction 14, and has a conductive end portion 72 facing the mating direction 14. Preferably, at least one contact pin is a spring pin 74 that has a tip 76 with a curved surface 78 facing the mating direction 14.

[0067] In Figure 1 In the illustrated embodiment, the electrical connector 1 can include at least two contact pins 70a, 70b, where at least one contact pin 70a is connected to the neutral line 80 of the electrical connector 1 (see Figure 4 ), and at least one additional contact pin 70b is connected to the ground line 82 of the electrical connector 1 (see Figure 4 ), thereby serving as the neutral contact 84 and the ground contact 86 of the electrical connector 1, respectively.

[0068] Additionally or alternatively, the electrical connector 1 may include at least one contact pad 92 having a conductive circular end face 94 facing the mating direction 14. Figure 2 The illustrated embodiment includes two such contact pads 92a, 92b, where at least one contact pad 92a is connected to the neutral line (not shown) of the electrical connector 1 and at least one additional contact pad 92b is connected to the ground line (not shown) of the electrical connector 1.

[0069] Each contact pin 70a, 70b may be mirror - imaged in terms of position and size with respect to the corresponding contact pads 92a, 92b of the mating connector 10. This is shown in Figure 5 which is shown in. It can also be seen from Figure 5 that the contact pins 70 and / or the contact pads 92 may be arranged within a circular space 88 between the center 44 of the substrate 26 and the connection circumference 90 of the contact elements 3a, 3b, 3c and / or the corresponding contact elements 4a, 4b, 4c.

[0070] Further referring to Figure 1 , the electrical connector 1 may include a part of the coupler 95, such as an active part 98 of the magnetic coupler 96, such as an electromagnet 100, which is preferably concentrically attached to the neutral 44 of the substrate 26 for attracting the mating connector 10, as shown in Figure 3 and Figure 4 shown. In this case, the mating connector 10 may be constituted by the electrical connector 1 according to the embodiment shown in Figure 2 . In particular, the mating connector 10 may include a passive part 102 of the magnetic coupler 96, such as a mating magnetic element 104. Thus, the magnetic force 105 of the magnetic coupler 96 can be utilized to generate a contact force 106 between the contact elements 3a, 3b, 3c of the electrical connector 1 and the corresponding contact elements 4a, 4b, 4c of the mating connector 10.

[0071] Additionally or alternatively, the electrical connector 1 may include a mechanical locking device (not shown) of a mechanical coupler (not shown), while the mating connector 10 may include complementary mechanical means of a mechanical coupler (not shown).

[0072] In Figure 3 and Figure 4 , a connector assembly 2 is shown, which includes the electrical connector 1 of the embodiment of Figure 1 and the electrical connector 1 according to the embodiment of Figure 2The mating connector 10 of the embodiment. It can be seen that the contact surfaces 5a, 5b, 5c of the electrical connector 1 face outward relative to the central axis 46, while the corresponding contact surfaces 11, 11a, 11b, 11c of the mating connector 10 face inward relative to the central axis 46. Therefore, all the contact points between the contact surfaces 5a, 5b, 5c of the electrical connector 1 and the corresponding contact surfaces 11a, 11b, 11c of the mating connector 10 are arranged on the opposite surfaces 48, 50 of the same truncated triangular pyramid 52 (see Figure 1 and Figure 2 ).

[0073] Figure 5 Fig. shows another possible embodiment of the connector assembly 2, wherein the electrical connector 1 further includes a connector housing 108. The connector housing 108 at least partially surrounds the three contact elements 3a, 3b, 3c of the electrical connector 1. In particular, the connector housing 108 can be a connector shell 110 or a connector housing 112, which is fixedly attached to the substrate 26. In Figure 5 the illustrated embodiment, the outer wall 114 of the connector housing 108 extends along the outer periphery 116 of the substrate 26 and protrudes in the shape of a hollow cylinder 118 along the mating direction 14.

[0074] Alternatively, the connector housing 108 can be spring-loaded and movably attached to the substrate 26. In Figure 6 , a possible embodiment of the electrical connector 1 with such a spring-loaded connector housing 120 is shown. It can be seen that the connector housing 108 is attached to the substrate 26 via a spring 122. Therefore, the spring-loaded connector housing 120 can move from a position 124 that protects the three contact elements 3a, 3b, 3c in the un-mated state to a position 126 that does not cover the three contact elements 3a, 3b, 3c in the mated state (as shown by the dashed line). In summary, the connector housings 108, 120 can be retracted against the mating direction 14 before or during the mating process.

[0075] As further visible in Figure 5 , the outer wall 114 can have a chamfered outer edge 128 that tapers in the mating direction 14. The mating connector can include a mating housing (not shown) having a socket opening (not shown) with a chamfered inner edge (not shown), which is configured to serve as a centering aid together with the chamfered outer edge 128 during the mating process.

[0076] Reference numerals

[0077] 1 Electrical connector

[0078] 2 Connector assembly

[0079] 3, 3a, 3b, 3c Contact elements

[0080] Contact elements corresponding to 4, 4a, 4b, 4c

[0081] Contact surfaces 5, 5a, 5b, 5c

[0082] Surface normal vectors 6, 6a, 6b, 6c

[0083] First vector components 7, 7a, 7b, 7c

[0084] Second vector components 8, 8a, 8b, 8c

[0085] 9 Convex protrusion

[0086] 10 Mating connector

[0087] Corresponding contact surfaces 11, 11a, 11b, 11c

[0088] 12 Circumferential direction

[0089] 14 Mating direction

[0090] 16 Height

[0091] 18 Horizontal

[0092] 26 Substrate

[0093] 28 Contact portion

[0094] 30 Termination portion

[0095] 32 Slit

[0096] 34 Outer edge

[0097] 36 Opposite edge

[0098] 38 Receptacle

[0099] 40 Gap

[0100] 42 Mechanical adjacent point

[0101] 44 Center

[0102] 46 Central axis

[0103] 48 Outer surface

[0104] 50 Inner surface

[0105] 52 Frustum of a triangular pyramid

[0106] 54 Flat portion

[0107] 56 Base-like block

[0108] 58 Mounting surface

[0109] 60 Mechanical support

[0110] 64 Ball protrusion

[0111] 66 Pit

[0112] 68 Vertex

[0113] 70, 70a, 70b Contact pins

[0114] 72 End portion

[0115] 74 Spring pin

[0116] 76 Tip

[0117] 78 Curved surface

[0118] 80 Neutral line

[0119] 82 Ground wire

[0120] 84 Neutral contact

[0121] 86 Ground contact

[0122] 88 Circular shape

[0123] 90 Connecting outer periphery

[0124] 92, 92a, 92b Contact pads

[0125] 94 End face

[0126] 95 Coupler

[0127] 96 Magnetic coupler

[0128] 98 Effective portion

[0129] 100 Electromagnet

[0130] 102 Passive portion

[0131] 104 mating electromagnetic element

[0132] 105 Magnetic force

[0133] 106 Contact force

[0134] 108 Connector housing

[0135] 110 Connector shell

[0136] 112 Connector housing

[0137] 114 Housing wall

[0138] 116 Outer periphery

[0139] 118 Hollow cylinder

[0140] 120 Spring-loaded connector housing

[0141] 122 Spring

[0142] 124 Position

[0143] 126 Position

[0144] 128 Chamfered outer edge

Claims

1. An electrical connector (1) configured to mate with a mating connector (10) along a mating direction (14) and including at least two contact elements (3), each contact element (3) having a contact surface (5), wherein each contact surface (5) is at least partially inclined with respect to the mating direction (14), and wherein the at least two contact elements (3) are spaced apart from each other along a circumferential direction (12) with respect to the mating direction (14), wherein, The electrical connector (1) includes a substrate (26), the substrate (26) includes at least one receptacle (38), and at least two contact elements (3) are attached to and supported on the receptacle, wherein at least one receptacle protrudes from the substrate in a mating direction and is formed monolithically by the substrate.

2. The electrical connector (1) according to claim 1, wherein the at least two contact elements (3) are separate, and at least one gap (40) is formed between the at least two contact elements (3).

3. The electrical connector (1) according to claim 1, wherein the at least two contact elements (3) extend through the substrate (26) along the mating direction (14).

4. The electrical connector (1) according to claim 3, wherein each contact element (3) is disposed on a separate receptacle (38).

5. The electrical connector (1) according to any one of claims 2 to 4, wherein the contact surfaces (5) of the at least two contact elements (3) face either inwards or outwards with respect to the center (44) of the substrate (26).

6. The electrical connector (1) according to any one of claims 1 to 4, wherein the at least two contact elements (3) have the same height (16) with respect to the mating direction (14).

7. The electrical connector (1) according to any one of claims 1 to 4, wherein each contact surface (5) of the at least two contact elements (3) has at least one convex protrusion (9).

8. The electrical connector (1) according to any one of claims 1 to 4, wherein each contact surface (5) of the at least two contact elements (3) has a plurality of convex protrusions (9), and all vertices (68) of the plurality of convex protrusions (9) are arranged on the surface of either a polyhedron or a solid of revolution.

9. The electrical connector (1) according to any one of claims 1 to 4, wherein the electrical connector (1) further includes a part (98, 102) of a coupler (95), and the coupler (95) is either a magnetic coupler (96) or a mechanical coupler.

10. The electrical connector (1) according to any one of claims 1 to 4, wherein the electrical connector (1) further includes at least one contact pin (70), and the contact pin is movable along the mating direction (14) and has an end portion (72) facing the mating direction (14).

11. The electrical connector (1) according to claim 10, wherein the electrical connector (1) further includes at least one contact pad (92), and the contact pad has an end face (94) facing the mating direction (14).

12. A connector assembly (2) comprising an electrical connector (1) according to any one of claims 1 to 11, wherein the contact surfaces (5) of at least two contact elements (3) face outwards, the connector assembly (2) further comprising a mating connector (10) according to any one of claims 1 to 11, wherein the contact surfaces (11) of at least two contact elements (4) face inwards, and wherein all contact points between the contact surface (5) of the electrical connector (1) and the contact surface (11) of the mating connector (10) are arranged on the surface of one of a polyhedron and a solid of revolution.

13. The connector assembly (2) according to claim 12, wherein one of the connectors (1, 10) is a ground-side connector of a conductive charging system and the other connector (1, 10) is a vehicle-side connector of the conductive charging system.

14. A charging robot comprising a robotic arm and an electrical connector (1) according to any one of claims 1 to 11, wherein the electrical connector (1) is mounted on an end portion of the robotic arm.

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