Discharge plug for battery of electric bicycle

Abstract

The present invention relates to a plug-in system (1), comprising a plug-in connector (2) and a mating plug-in connector (3) which can be plugged together with the plug-in connector, wherein the plug-in connector (2) has a housing having a flange (5) and a frame (7) comprising at least one contact cavity (8), in which a contact counterpart (9) is arranged, and the mating plug-in connector (3) has a housing and a frame (12) comprising a contact cavity (13), in which at least one contact counterpart (14) is arranged, characterized in that each contact counterpart (14) of the mating plug-in connector (3) is surrounded by a sheath (15), which surrounds the contact counterpart (14) except for an insertion area for a matching contact counterpart (9) of the plug-in connector (2).

Description

Technical Field

[0001] The present invention relates to a plug-in system, which comprises a plug-in connector and a mating plug-in connector that can be plugged together with the plug-in connector, wherein the plug-in connector has a housing and a frame comprising at least one contact cavity, in which a contact counterpart is arranged, and the mating plug-in connector has a housing and a frame comprising a contact cavity, in which at least one contact counterpart is arranged. Background Art

[0002] In particular, the invention relates to a discharge plug for batteries of electric bicycles (E-Bike batteries). Batteries with a nominal voltage of 42 volts (or higher if necessary) should be able to be pivoted inwards into the frame of the bicycle. Furthermore, the contacts must be protected against contact according to the known IPXXB standard, since voltages equal to or greater than 42 V occur here. Since this voltage can occur both on the contact pin side (plug connector) and on the socket side (mating plug connector), the required contact protection applies to both plug-in counterparts of the plug-in system. Furthermore, the discharge interface must meet the sealing requirements according to IP67 in the plugged state. Summary of the invention

[0003] The object of the present invention is to provide a plug-in system comprising a plug-in connector and a mating plug-in connector which can be plugged together with the plug-in connector and which has improved safety with regard to the plug-in process.

[0004] The object is achieved by a plug-in system, which comprises a plug and a mating plug that can be plugged together with the plug, wherein the plug has a first housing, the first housing has a first flange and a first frame comprising at least one first contact cavity, a first contact counterpart is arranged in the first contact cavity, the mating plug has a second housing and a second frame comprising a second contact cavity, at least one second contact counterpart is arranged in the second contact cavity, each second contact counterpart of the mating plug is surrounded by a sheath, the sheath covers the second contact counterpart except for the insertion of the matching first contact counterpart of the plug. The plug-in system is surrounded by an area outside the plug-in system, and is configured so that the plug-in connector can be docked with the mating plug-in connector at different angles deviating from the longitudinal axis of the plug-in system and subsequently pivoted inwardly into the mating plug-in connector. The surrounding mating front end of the second housing of the mating plug-in connector has a surrounding ramp, which corresponds to the front end ramp of the surrounding first frame of the first housing of the plug-in connector. A radially protruding sealing element is provided in the free end area of ​​the first frame of the plug-in connector, and the plug-in connector can slide on the ramp of the mating plug-in connector with the sealing element when pivoting inwardly and thereby assist the plug-in connector to pivot inwardly into the mating plug-in connector.

[0005] According to the invention, each contact counterpart of the mating connector is surrounded by a sheath, which surrounds the contact counterpart except for the insertion area for the mating contact counterpart of the connector. In a manner known per se, the connector has at least one contact chamber, in which the contact counterpart arranged according to the invention is set back or retracted relative to the free end of the connector frame (in order to prevent a finger, a part of the hand, a tool or the like from touching the at least one contact counterpart, thereby ensuring contact protection), and according to the invention, each contact counterpart of the mating connector is surrounded by a sheath, and all contact counterparts (one contact counterpart or more than one contact counterpart) are surrounded by a frame. The sheath can prevent the contact counterpart from being touched, so that contact protection is also achieved in the mating connector. However, the part of the contact counterpart that is to be plugged together with the corresponding contact counterpart of the connector for the purpose of electrical contact is exposed, so that the contact counterpart of the connector can be inserted into this plug-in area of ​​the contact counterpart of the mating connector. In this arrangement of the mating connector, some or preferably all of the contact partners can, but not necessarily, be moved back relative to the freely upright surrounding edge of the frame, so that the surrounding edge of the frame prevents the exposed insertion area of ​​the at least one contact partner of the mating connector from being contacted.

[0006] The plug connector and the mating plug connector can be arranged on the end of the cable, and the cable has at least one electrical conductor respectively, which is in electrical contact with a matching contact counterpart. This arrangement can be designed to be freely movable. It is also conceivable that the plug connector and / or the mating plug connector, preferably both, are fixed on the installation position that meets the regulations. One installation position is, for example, a vehicle, especially a component of an electric bicycle (such as a frame of a bicycle), and another installation position is a housing of an energy source (such as a battery). The housing of the plug connector and the mating plug connector is designed to allow them to be plugged together in an axial direction in an aligned manner. Since the battery is often inserted into the frame in an electric bicycle or in other arrangements of an electric bicycle or in general, the plug connector needs to be obliquely docked to the mating plug connector and further moved into the mating plug connector. This movement is a pivoting movement inward, so that when the two elements are finally plugged together in accordance with regulations and reach their terminal position, the plug connector or its housing is aligned and arranged in the mating plug connector or its housing.

[0007] In order to achieve the pivotability of the plug-in system, a contact system is selected which allows an inclined insertion angle of 10° (+ / -50%, preferably + / -25%, preferably + / -15%, more preferably + / -5%, in particular exactly 10°). The housing parts are then provided with an entry chamfer so that the plug-in system can be pivoted inwards. In order to ensure contact protection according to IPXXB despite the exposed contact pins, the contacts are individually encapsulated according to the invention. Contact with standard fingers is thus avoided. The encapsulation of the contact pins makes it possible for the socket contacts to be located in a closed contact cavity as usual. The contact cavities of the socket are arranged in separate arches, which are grooved at certain locations in order to be able to accommodate the reinforcing ribs of the contact pin encapsulation geometry.

[0008] For the above-mentioned insertion or inward pivoting process, the present invention further provides that a sealing element is provided in the free end region of the connector frame and a ramp that cooperates with the sealing element during the plug-in process is provided in the free end region of the mating connector frame. The presence of the ramp has the advantage that the connector can be guided further into the mating connector after being inserted into the mating connector. Thus, the ramp achieves defined guidance during the plug-in process. This guidance is further strengthened by providing a deformable sealing element in the free end region of the connector frame. The outer contour of the sealing element can first slide over the ramp until it slides into the inner contour of the mating connector frame, thereby significantly improving the insertion or inward pivoting process through defined guidance, and after the insertion or inward pivoting is carried out, the sealing element also seals the inner area of ​​the plug-in system (inside the frame of the connector and the mating connector).

[0009] In a further development of the invention, it is provided that the plug connector and / or the mating plug connector has a latching element for latchingly fixing it in its intended installation position. As a result, the plug connector and / or the mating plug connector can be quickly and easily installed in an installation position, such as a housing of an electric bicycle frame and / or a housing of another installation position, such as a housing of a battery.

[0010] In a further development of the invention, it is provided that the housing of the plug connector has a flange in which at least one opening is provided and / or the housing of the mating plug connector has a flange in which at least one opening is provided. As a result, the plug connector and / or the housing of the mating plug connector can be arranged in the installation position simply, quickly and permanently by means of a screw connection (defined and correctly positioned arrangement in the installation position is ensured by the flange) and fixed (by means of screws that can be passed through the corresponding openings) in the installation position. Instead of a screw connection, a rivet connection can also be used.

[0011] In order to assist the permanent fixation of the plug connector and / or the mating connector in its respective installation position and also ensure operational safety at the installation position, in a further development of the invention, it is additionally provided that the plug connector and / or the mating connector has a sealing element which, after being fixed in its intended installation position, is arranged between the installation position and the housing of the plug connector or the mating connector. In cooperation with the sealing element, by lockingly fixing the plug connector or the mating connector in its installation position, not only the desired sealing but also a permanent fixation can be achieved, which contributes to increased operational safety.

[0012] The invention therefore relates to a plug connector or a mating plug connector having at least one contact counterpart, preferably a plurality of contact counterparts, which is pivotably arranged on a base, characterized in that each contact counterpart is encapsulated in order to achieve contact protection in the unplugged state. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] An embodiment of the plug-in system according to the present invention is explained below with reference to the accompanying drawings.

[0014] Figures 1 to 5 A plug-in system is shown. Figure 2 and 3 A detailed view of the plug connector 2 is shown in FIG. Figure 4 and 5 1 also shows the design of the corresponding mating connector 3 in different views.

[0015] Figure 6 Another design of the mating plug connector 3 is shown, and Figure 7 A cross-section of the mating connector 3 is shown.

[0016] Figure 8 , Fig. 9 and Fig.10 The plug-in system 1 according to the invention is shown with its correspondingly designed plug-in connector 2 and its correspondingly designed mating plug-in connector 3 plugged together in different ways.

[0017] Fig.11 and 12 Plug system 1 is shown in FIG. 1 , ready for operation.

[0018] Fig.13 Different views of a mating connector 3 according to the invention are shown and Fig.14 Different views of a corresponding plug connector 2 according to the invention are shown. DETAILED DESCRIPTION

[0019] As shown in detail in the figure, Figures 1 to 52 shows a plug system 1, which shows a plug connector 2 and a mating plug connector 3 which can be plugged together with the plug connector. The two elements of the plug system 1 are respectively arranged on the ends of a single-core or multi-core cable 4.

[0020] exist Figure 2 and 3 , a detailed view of the plug connector 2 is shown in FIG. The housing of the plug connector 2, which is not shown in detail, has a flange 5, which has at least one opening 6, in the present embodiment, one opening 6 at each end of the rectangular flange 5, through which the housing of the plug connector 2 can be fixed in its installation position, for example by means of screws. The at least one opening 6 can be present, but does not necessarily have to be present. In particular, the opening can be omitted if the plug connector 2 is fixed in its installation position by at least one latching element, adhesive bonding, press fit or similar connection.

[0021] In addition, the housing of the plug connector 2 has a surrounding frame 7, in which at least one contact cavity 8 is provided, in this embodiment, five contact cavities 8 are provided, and a contact counterpart 9 is provided in each contact cavity 8. It is shown that each contact counterpart 9 is set back relative to the free end of the surrounding frame 7 and the partition formed inside the frame for forming the at least one contact cavity 8, so that compared with the front end of the housing of the plug connector 2 in the region of the surrounding frame 7, the end of the contact counterpart 9 cannot be touched by hand, fingers or the like.

[0022] exist Figure 4 and 5 , the design of the matching mating connector 3 is also shown in different views. The mating connector 3 also has a housing, which has a flange 10 (which may have, but does not necessarily have to have, as in the connector 2). Similar to the flange of the connector 2, the flange 10 of the mating connector 3 also has an opening 11 at each of its four corners. In addition, there is a surrounding frame 12, which forms a single contact chamber 13, into which the surrounding frame 7 of the connector 2 can be inserted together with its contact chamber and contact counterpart.

[0023] According to the design of the plug connector 2, at least one contact counterpart, here five contact counterparts 14 protrude from the bottom, from which the frame 12 extends. In order to achieve contact protection, each contact counterpart 14 is surrounded by a sheath 15. The corresponding sheath 15 almost completely surrounds a contact counterpart 14, except for the insertion area for the corresponding contact counterpart 9 of the plug connector 2. Preferably, each sheath 15 is designed so that it surrounds the outer surface and the end face facing away from the bottom of the corresponding contact counterpart 14, but at the same time leaves an opening on the end face facing away from the bottom for inserting the contact counterpart of the plug connector 2.

[0024] Especially in Figure 4 and 5 as well as Fig.13 (bottom left) shows that in addition to the insertion opening, two areas are left open on the side of the sheath 15 for receiving locking lances of the contact counterparts 14 (in this embodiment, especially socket contacts), which are used to initially lock the contact counterparts in the contact chambers of their mating connectors. These free areas can, but do not necessarily, exist.

[0025] exist Figure 6 Another design of the mating plug connector 3 is shown in FIG. It can be seen that the housing of the mating plug connector 3 has a sealing element 16 below its flange 10. The housing of the mating plug connector 3 is Figure 6 17. A latching element 18 is provided on one side of the housing 17. The latching element 18 is arranged in a frame-shaped recess formed by the housing 17. The mating connector 3 can be fixed in its installed position in a prescribed manner by means of the at least one latching element 18. The same design as the mating connector 3 can also be provided in the connector 2.

[0026] Figure 7 1 shows a cross-sectional view of the mating connector 3. In this illustration, the mating connector 3 is fixed in its installation position 20 in a prescribed manner by means of the latching element 18. It can also be seen that the outer contour of the housing 17 is sealed relative to the inner contour of the installation position 20 by means of the sealing element 16. In addition, in this Figure 6 It can be clearly seen that the contact mating piece 14 is surrounded by the sheath 15, and the end of the contact mating piece 14 pointing in the plugging direction (i.e. its end face) is moved back relative to the front end of the sheath. In order to simplify docking and plugging, the opening of the installation position 20 has a chamfer 21, which makes it easier to insert the mating connector 3 into the installation position 20. In order to increase this effect, the surrounding end of the housing 17 facing the cable 4 is also provided with a corresponding chamfer or slope. This is also Figure 7 The chamfer 21 , which can be selected to be very large, forms the surface required for the compression sealing element 16 , in particular an O-ring, in order to arrange the plug connector 2 or the mating plug connector 3 in the installation position 20 with little or no play.

[0027] exist Figure 8 , 9 10 shows that the plug-in system 1 according to the invention with its correspondingly designed plug-in connector 2 and its correspondingly designed mating plug-in connector 3 can be plugged together in different ways. Not shown, but in principle possible, is that the plug-in connector 2 is docked onto the mating plug-in connector with its longitudinal axis aligned with the longitudinal axis of the mating plug-in connector 3 and then moved into it.

[0028] But in Figure 82 and the mating connector 3 are shown to be moved obliquely to each other (here 5°) and plugged together. In order to realize this docking process and the subsequent inward pivoting process, a part of the housing of the connector 2 (also designed in a frame-like manner) protrudes from the front end of the installation position 20 where the connector 2 is located. The mating connector 3 is also arranged with its housing in the matching installation position 20. Figure 7 ,according to Figure 8 The mating connector 3 is fixed in the installation position 20 by means of its latching elements 18 , specifically with the sealing element 16 arranged in between.

[0029] As an alternative, it is conceivable that the plug connector 2 or the mating plug connector 3 is respectively fixed in the installation position 20 only by means of a latching element, in particular by means of a latching element 18, without providing a sealing element in the form of a seal and / or gap compensation and / or tolerance compensation. For example, the sealing element 16 may not have this special form of an O-ring in the form of a lip seal, but may have another form of a lip seal.

[0030] In order to enable the docking process of the plug connector 2 and the subsequent pivoting process inward into the mating connector 3 , the circumferential mating front end of the housing of the mating connector 3 has a circumferential ramp 22 .

[0031] This ramp 22 of the mating connector 3 corresponds to the front ramp of the surrounding frame of the housing of the connector 2. Therefore, the corresponding ramps of the connector 2 and the mating connector 3 can slide on each other during docking and subsequent inward pivoting. It does not matter from which direction the connector 2 is docked to the mating connector 3 (or vice versa), because both ramps are surrounding. In this case, the housings of the connector 2 and the mating connector 3 have a symmetrical cross-section (such as a square, circular or similar shape) about their plug-in axis.

[0032] However, the plug-in system (also referred to as contact system) of this embodiment only allows the above-mentioned inclined insertion angle of, for example, 15° on one axis. On the other axis, only an inclined insertion angle deviating from this angle (less than or greater than 15°, such as only 5°) can be achieved through the plug-in system. In this case, the housings of the plug connector 2 and the mating plug connector 3 have an asymmetric cross section (such as a rectangular, oval or similar shape) with respect to their plug-in axis.

[0033] Furthermore, for a defined plugging process, the inward pivoting should take place from a defined direction (e.g. Figures 7 to 9 shown).

[0034] The inward pivoting process after docking is also assisted by the sealing element 23 in the front end region of the protruding frame of the plug connector 2. When pivoting inward, the plug connector 2 can slide with the sealing element 23 on the ramp 22 and then on the inner contour of the housing frame of the mating plug connector 3. As a result, not only is the inward pivoting process made easier, but the inner region of the plugged-in plug system 1 is effectively sealed by means of the sealing element 23 to achieve or assist longitudinal waterproofing.

[0035] The same process as above also occurs in Fig. 9 and 10 During the docking and inward pivoting process shown, this means that the plug connector 2 can dock and pivot inwardly at different angles away from the longitudinal axis of the plug-in system 1 .

[0036] Furthermore, if we look at it another way Fig.10 , 9 8 (i.e. in this time sequence, rather than observing them separately as described above), it can be seen that the plug connector 2 can first be docked at a larger angle relative to the mating plug connector 3. This is exemplified in Fig.10 When the front ends of the connector 2 and the mating connector 3 are in contact ( Fig. 9 ), the two elements still do not have to be aligned with each other. Fig. 9 As shown in the figure, in the docking ( Fig.10 ) and then decreases further during the subsequent inward pivoting ( Figure 8 ), so that finally, after the plug-in process is completely completed, the plug connector 2 is plugged together with the mating plug connector 3 in accordance with the regulations to form a plug-in system 1 that is ready for operation. Fig.11 and 12 Shown in.

[0037] When observing Fig.10 , 9 The contact protection can also be clearly seen in Figures 1 and 2. Both the at least one contact partner of the plug connector 2 and the at least one matching contact partner of the mating plug connector 3 are effectively protected from contact by their retreat or their sheath before the two elements are completely plugged together. Figure 8 It can also be clearly seen that shortly after the plug connector 2 is docked onto the mating plug connector 3 (or vice versa), the contact counterpart 9 of the plug connector 2 begins to move into the contact counterpart 14 of the mating plug connector 3, until Figure 8 Prior to the state shown, the contact counterparts 9, 14 were contact-protected and only thereafter began to be effectively connected to one another, wherein on the one hand they were in electrical contact but on the other hand they were still effectively contact-protected as before by the retreat of the contact counterpart 9 in the plug connector 2 and the sheath of the contact counterpart 14 of the mating plug connector 3.

[0038] For the sake of completeness, Fig.13 Different views of the mating connector 3 according to the invention are shown again and Fig.14 Different views of a corresponding plug connector 2 according to the invention are shown.

[0039] Reference numerals list

[0040] 1 Plug-in system

[0041] 2 Connectors

[0042] 3 Mating connector

[0043] 4 Cables

[0044] 5 Flange

[0045] 6 Opening

[0046] 7 Framework

[0047] 8 Contact chamber

[0048] 9 Contact mating parts

[0049] 10 Flange

[0050] 11 Opening

[0051] 12 Framework

[0052] 13 Contact chamber

[0053] 14 Contact mating parts

[0054] 15 Sheath

[0055] 16 Sealing element

[0056] 17 Housing

[0057] 18 Locking element

[0058] 19 Frame-shaped groove

[0059] 20 Installation location

[0060] 21 Chamfer

[0061] 22 Slope

[0062] 23 Sealing element

Claims

1. A plug-in system (1), comprising a plug connector (2) and a mating plug connector (3) that can be plugged together with the plug connector, the plug connector (2) having a first housing, the first housing having a first flange (5) and a first frame (7) comprising at least one first contact cavity (8), a first contact counterpart (9) being arranged in the first contact cavity, the mating plug connector (3) having a second housing and a second frame (12) comprising a second contact cavity (13), at least one second contact counterpart (14) being arranged in the second contact cavity, each second contact counterpart (14) of the mating plug connector (3) being surrounded by a sheath (15), the sheath surrounding the second contact counterpart (14) except for an insertion area for a matching first contact counterpart (9) of the plug connector (2), characterized in that The plug-in system (1) is designed so that the plug-in connector (2) can be docked with the mating plug-in connector (3) at different angles deviating from the longitudinal axis of the plug-in system (1) and subsequently pivoted inwardly into the mating plug-in connector (3), the surrounding mating front end of the second shell of the mating plug-in connector (3) having a surrounding ramp (22), the ramp (22) of the mating plug-in connector (3) corresponding to the front end ramp of the surrounding first frame (7) of the first shell of the plug-in connector (2), and a radially protruding first sealing element (23) is provided in the free end area of ​​the first frame (7) of the plug-in connector (2), and the plug-in connector (2) can slide on the ramp (22) of the mating plug-in connector (3) when pivoting inwardly and thereby assist the plug-in connector (2) to pivot inwardly into the mating plug-in connector (3).

2. The plug-in system (1) according to claim 1, characterized in that The plug connector (2) and / or the mating plug connector (3) has a latching element (18) for latching and fixing it in its intended installation position.

3. The plug-in system (1) according to claim 2, characterized in that The plug connector (2) and / or the mating plug connector (3) has a second sealing element (16) which, after being fixed in its intended installation position, is arranged between the installation position and the first housing of the plug connector (2) or the second housing of the mating plug connector (3).

4. The plug-in system (1) according to claim 1 or 2, characterized in that: At least one opening (6) is provided in the first flange, and / or the second housing of the mating connector (3) has a second flange (10) in which at least one opening (11) is provided.

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