Threaded plug-in connector

Abstract

Plug connection system comprising a plug connector (1) and a mating plug connector which can be plugged together with the plug connector (1), the plug connector (1) having a housing (2) in which an electrical conductor (3) is inserted, wherein the electrical conductor (3) is in electrical contact with a contact pair (4) which is likewise arranged in the housing (2) by abutment of their surfaces against one another, wherein the contact pair (4) is in particular in contact with the contact pair of the mating plug connector with its annular end face (5) such that the end faces abut against one another and the plug connector (1) is plugged together with the mating plug connector, wherein this plugging together is facilitated and assisted by a fastening mechanism, in particular a screw (6), wherein an insulation, in particular an insulation element (12), or a coating of the screw (6) is provided which has the effect that the screw (6) does not come into contact with voltage-carrying components, such as the electrical conductor (3) and / or the contact pair (4).

Description

Technical Field

[0001] The present invention relates to a plug-in connection system, which includes a plug-in connector and a mating plug-in connector that can be plugged into the plug-in connector. Background Technology

[0002] Such a plug-in connection system is known from U.S. Patent 9,048,551 B2, and is described in this patent application. Figure 1 As shown in the image.

[0003] In order to transmit large current, it is necessary not only to plug the plug connector into the matching plug connector, but also to provide at least one fastening mechanism. The plug-in process is facilitated and thus assisted by the fastening mechanism, and the plug connector is securely fixed in the matching plug connector after the plug-in process is completed.

[0004] Such plug-in connection systems are particularly useful in high-voltage applications, such as those exceeding 42 volts, and / or for transmitting large currents. Therefore, care must be taken to avoid touching energized components. This applies both when the plug-in connection system is plugged in and, more importantly, when the plug-in connector and its mating connector are not yet plugged in.

[0005] Therefore, as disclosed in, for example, US 9,048,551 B2, there is a need to protect energized components, and in particular fastening mechanisms, from contact. These fastening mechanisms, such as a screw, are made of metal because, although they should not transmit voltage or current, they provide the necessary tightening and holding forces, which are not only necessary during the mating process but must also be continuously applied throughout the use of the mating connection system.

[0006] US 9,048,551 B2 specifies that the fastening mechanism is a screw, which is first covered by an insulating sleeve, and secondly, an insulating cover made of plastic is provided on the free front end of the screw pointing in the direction of the mating connector. Through the insulating sleeve that mates with the insulating cover, the energized components (the contacts of the connector and the screw) are effectively protected from contact, especially from finger contact. Summary of the Invention

[0007] The object of the present invention is to provide a different method for providing contact protection for such plug connections, particularly for their plug connectors.

[0008] This objective is achieved, in part, by having the fastening mechanism, particularly the screw, constructed entirely of a non-conductive material (e.g., plastic). Such a fastening mechanism, especially the screw, can be easily and economically manufactured from a non-conductive material, making it particularly suitable for mass production. Furthermore, if the tightening force required to connect the plug-in connector to its mating plug-in connector is not too high, a fastening mechanism made entirely of a non-conductive material can be considered. However, when the tightening force exceeds a certain limit, a fastening mechanism, particularly a screw, made of a non-conductive material cannot be considered, as the necessary tightening force cannot be achieved using such a material. Additionally, such a material is unsuitable, especially when there are requirements for the long-term stability of the plug-in connection system.

[0009] On the other hand, the aforementioned objective is also achieved by using a fastening mechanism, particularly a screw, whose core is made of a metallic material, preferably with a non-conductive coating on its surface, at least in areas that may be touched. This could be, for example, a nano-coating, a plastic injection-molded encapsulation, or something similar. Using such a fastening mechanism, particularly a screw, with its core made of a metallic material, a fastening force that cannot be achieved using plastic materials can be achieved without any problems. In particular, when a plug connector is plugged into a mating plug connector and placed in a durable connection using a fastening mechanism, the long-term stability of the required plug connection system can also be achieved using a fastening mechanism, particularly a screw, with its core made of a metallic material. Simultaneously, contact protection is provided by the non-conductive coating.

[0010] Furthermore, in an alternative embodiment, this objective is achieved by the following: the fastening mechanism, particularly the screw, is made of a metallic material as in the prior art; however, it is arranged within the connector insulated from the energized components of the connector, particularly its electrical conductors and / or its contacts, by additional means. For this purpose, a corresponding insulating element is provided, for example, made of plastic. In this way, additional means for achieving contact protection, such as the cap 7 fitted onto the end of the screw in the prior art, are omitted.

[0011] In a particularly important structural design of the present invention, the insulating element has an annular flange, and an insulating sleeve is adjacent to the annular flange of the insulating element, wherein the annular flange and the insulating sleeve are made of different non-conductive materials. The outer diameter of the annular flange is larger than the opening for the insulating element in the electrical conductor, particularly in the conductive rail, while the outer diameter of the insulating sleeve substantially corresponds to the inner diameter of the opening for the insulating element, so that the insulating element can be inserted into the opening in the electrical conductor. On the one hand, to avoid leakage current and achieve contact protection; on the other hand, to utilize the necessary fastening force achieved by the fastening mechanism, particularly screws, and to ensure long-term stability, the annular flange of the insulating element is made of a non-conductive material different from that of the insulating sleeve. Because the area of ​​the insulating sleeve is not subjected to the fastening force and pressure of the fastening mechanism, it can be made of a different, particularly more economical, material, such as a plastic. The area of ​​the insulating element subjected to the fastening force and pressure and also subjected to the continuous force in the plugged-in connection system, i.e., the annular flange, is made of a material capable of continuously withstanding these forces.

[0012] The plastic material of the insulating sleeve can be, for example, polybutylene terephthalate (PBT, or PTMT), polyetheretherketone (PEEK, a partially crystalline thermoplastic with very good mechanical properties, even under heat load, and characterized by a high continuous operating temperature), or similar materials. Therefore, the insulating sleeve may be composed entirely of one of the aforementioned materials. However, as an alternative, the insulating sleeve may be made of more than one material, for example, two or more materials. In this case, for example, the core of the insulating sleeve may be made of one of the aforementioned materials (possibly a metal), while the outer surface of the insulating sleeve is coated with or covered by a different material (in any case, an electrically insulating material).

[0013] In contrast, the annular flange of the insulating element is made of a harder material, such as ceramic or metallic materials. Since a ceramic material (e.g., alumina, Al₂O₃) is electrically insulating, the annular flange can be made of only this material, thus omitting, for example, the additional ceramic coating, although such a coating can certainly be applied. If the annular flange of the insulating element is made of a metallic material, this metallic material needs to be coated or encapsulated to make it non-conductive. Such encapsulation can be achieved, for example, by coating with plastic (as in materials used for insulating sleeves), but insulation can also be achieved through coating, anodizing, etc. For example, the core of the annular flange can be made of a metallic material (such as aluminum) that is anodized to achieve insulation. Nevertheless, the use of plastic materials for the annular flange is not excluded. Thus, materials such as "PEEK GF20" or "PEEK GF30," where the material is a polyetheretherketone (PEEK) reinforced with glass fiber, can be considered. An unfilled plastic (PEEK) can also be considered.

[0014] If the insulating element consists of multiple individual pieces, particularly two separate components—an annular flange and an insulating sleeve—then after these individual components, especially the two separate components made individually, they need to be assembled. This is done, for example, by press-fitting, bonding, or similar methods. For this purpose, the annular flange has a through-hole through which the insulating sleeve passes and is secured. This design is suitable for press-fitting the insulating sleeve with its outer surface into the through-hole in the annular flange. Here, the upper annular end of the insulating sleeve is advantageously flush with one surface of the annular flange. As an alternative, the upper annular end of the insulating sleeve can also be arranged on the surface of the annular flange and secured there.

[0015] As an alternative to the possibility of the insulating element being composed of two or more parts made of the aforementioned different materials, it is also possible to consider an insulating element consisting of only one part, and entirely made of a single insulating material, particularly PEEK GF20, PEEK GF30 (or similar materials), or a ceramic material, or an anodized metal material. Instead of anodizing the metal material, in the case of this single-part structural element, this metal material can also be made insulating by other methods (e.g., through varnish, plastic coating, or similar).

[0016] As already described in detail, the insulating sleeve consisting of one part and the insulating sleeve consisting of two or more parts may, for example, be made of only PEEK GF20 or PEEK GF30, or generally of a filled or unfilled plastic, and alternatively of other insulating materials. Attached Figure Description

[0017] Further structural designs of the invention will also be described in conjunction with the accompanying drawings.

[0018] The accompanying drawings illustrate not only one embodiment of the prior art ( Figure 1 An embodiment of the invention is also shown (). Figures 2 to 4 ). Detailed Implementation

[0019] exist Figure 1 The diagram illustrates an embodiment of the plug connector 1 known from the aforementioned U.S. patent. This plug connector has a housing 2 into which an electrical conductor 3 (e.g., a conductive rail designed for high-voltage applications) is inserted. The electrical conductor 3 is electrically contacted with a contact pair 4 also disposed in the housing 2, such that their surfaces abut each other. In this embodiment, the contact pair 4 is constructed as a sleeve, and its annular end face 5 (surrounding end face) may, but is not required to, contact the mating plug connector's (not shown) contact pair in such a way that the end faces, more precisely, the surfaces of these end faces abut each other. To achieve this, the plug connector 1 is plugged into a mating plug connector (not shown), wherein this plugging process is facilitated and assisted by a fastening mechanism, in this embodiment, constructed as a screw 6.

[0020] To prevent contact between the free end of the screw 6 and the contact point, a cover 7 is provided on the end, which is made of a non-conductive material, such as plastic.

[0021] In the end region away from the free end of the screw 6, i.e., in the region of the screw head, there is an additional cap 8, which also prevents contact with the screw 6. Furthermore, specifically for securing the cap 8, an additional cap 9 is provided on the housing 2. Optionally, the cap 9 and the housing 2 can also be constructed as a single unit.

[0022] To prevent contact between the contact pair 4, an insulating sleeve 10 made of the same non-conductive material is provided around the contact pair.

[0023] The contact pair 4 has a through hole for the screw 6, which has external threads 11 in its longitudinal extension. The screw 6 is screwed into a corresponding internal thread of the mating plug connector using the external threads 11, thereby achieving the mating process and permanently securing the plug connector in the mating plug connector (not shown).

[0024] The screw 6 is pressed tightly against the conductor 3 by the lower side of its annular flange, thereby pressing the conductor against the contact pair 4. Furthermore, this pressure, after the screw 6 is tightened, is transmitted to the contact pair of the mating connector, causing the annular end face 5 of the contact pair 4 to abut against the corresponding annular end face of the contact pair of the mating connector, achieving a defined contact force and thus a defined energy transfer.

[0025] As has been explained in detail, the disadvantage of this prior art is that a cover 7 must be provided to avoid contact with the voltage-carrying screw 6.

[0026] The above reference Figure 1 The prior art, which is known and has disadvantages, is described below with reference to Figures 2 to 4 An advantageous embodiment of the invention will be described.

[0027] With the structure of the plug connector 1 being basically the same, the present invention provides an insulating element 12, in Figure 2 The diagram illustrates the structure and arrangement of the insulating element in the plug connector 1. This insulating element 12 has a mechanism for the screw 6 (in...) Figure 2 (Not shown) The insulating element 12 does not contact any energized components (such as the conductor 3 and the contact pair 4). The insulating element 12 is arranged between the conductor 3 and the contact pair 4, particularly in the through-hole of the contact pair. The insulating element has a through-hole 13 for fastening, particularly for the screw 6. The insulating element has an annular flange 14 by which it rests against the surface surrounding the through-hole of the conductor 3. Below this flange 14 is a preferably circumferential guide ramp 15 so that the insulating element 12 can be correctly and precisely inserted into the hole in the conductor 3 (which is also configured here as a conductive rail).

[0028] The insulating element 12 is fixed in its conventional installation position, for example by inserting it into a through hole in the electrical conductor 3, bonding, pressing, tightening, or similar methods.

[0029] Figure 3 It shows the basis Figure 2The mating connector 1 is configured such that the screw 6 is now inserted. The screw 6 is positioned where the mating connector is not yet inserted or mounted on the mating connector 1. Since the insulating element 12 has no threads in its port 13, the external threads 11 of the screw 6 do not engage with the insulating element 12, allowing the external threads to move freely through the port 13. This advantageously achieves the effect that mounting the mating connector onto the mating connector 1 places the screw 6 within the observation... Figure 3 When pressed upwards, a distance D is created between the surface of the annular flange 14 and the annular lower side of the screw head of the screw 6.

[0030] After the mating connector 1 is abutted against and partially inserted into the mating connector, the screw 6 can be operated manually (because the screw is inherently anti-electric shock due to its construction design (especially its material and / or its coating), and optionally additionally through the cap 8) or with an electrically insulating tool (with or without the cap 8), thereby reducing the distance D, preferably to zero, by turning the screw 6 to screw its external thread 11 into the corresponding internal thread of the mating connector housing or contact pair. Figure 4 As shown in the diagram.

[0031] Therefore, in Figure 4 As can be clearly seen, the lower side of the annular screw head of the screw 6 is pressed against the electrical conductor 3 via the insulating annular flange 14 of the insulating element 12, and from there against the contact pair 4, so that the annular end face 5 of the contact pair 4 is electrically and permanently fixed to the corresponding annular end face of the contact pair of the mating plug connector.

[0032] In order not to interfere with the fastening mechanism, especially the previous reference of screw 6 Figures 2 to 4 The axial movement described refers to the surface of the port 13 used for the fastening mechanism, particularly for the screw 6, which is designed to be smooth. This means that the port 13 has no threads.

[0033] Replacement of insulating element 12, as in Figure 2 As shown, the insulating element 12 is fixedly arranged on the electrical conductor 3 and / or contact pair 4. The insulating element may also be arranged below the screw head of the screw 6 and move with the screw. Alternatively, the insulating element 12 may itself have an internal thread corresponding to the external thread 11 of the screw 6. The insulating element 12 may also be configured as a separate component that is pushed onto the external thread 11 of the screw 6 and assembled with the screw.

[0034] Matching plug connectors can be arranged on the end of an electrical conductor, particularly the end of a conductive rail, just like plug connectors. However, matching plug connectors can also be components of electrical equipment, energy storage devices, especially electrical terminals of electric vehicle energy storage devices, or similar parts.

[0035] List of reference numerals

[0036] 1. Plug connector

[0037] 2. Shell

[0038] 3. Electrical conductors

[0039] 4 Contact pairs

[0040] 5. Annular end face

[0041] 6 screws

[0042] 7. Protective Cover

[0043] 8. Capping

[0044] 9. Capping

[0045] 10 Insulating sleeves

[0046] 11 External thread

[0047] 12 Insulating elements

[0048] 13. Slot

[0049] 14. Annular flange

[0050] 15. Surrounding Introducing Slope

Claims

1. A plug-in connection system, comprising: A plug connector (1) and a mating plug connector that can be plugged into the plug connector, the plug connector (1) having a housing (2) into which an electrical conductor (3) is inserted, the electrical conductor (3) being in electrical contact with a contact pair (4) also arranged in the housing (2) such that their surfaces abut against each other, wherein the contact pair (4) contacts the contact pair of the mating plug connector such that their end faces abut against each other, and the plug connector (1) is plugged into the mating plug connector, wherein this plugging process is facilitated and assisted by a fastening mechanism, i.e., a screw (6), characterized in that: an insulator, i.e. an insulating element (12), is provided, the insulating The body ensures that the screw (6) does not come into contact with any energized component, namely the electrical conductor (3) and / or the contact pair (4). The insulating element (12) has a through-hole (13) for the screw (6), through which the screw (6) can move freely, such that when the mating connector is mounted onto the mating connector (1), the screw (6) is pressed upward, thereby creating a distance (D) between the surface of the annular flange (14) of the insulating element (12) and the annular underside of the screw head of the screw (6). This distance (D) is reduced when the external thread (11) of the screw (6) is screwed into the housing of the mating connector or the corresponding internal thread of the contact pair.

2. The plug-in connection system according to claim 1, characterized in that: The core of the screw (6) is made of a metal material having a non-conductive coating on its surface, at least in the areas where it may be touched, as an insulator, or the screw is made entirely of a non-conductive material.

3. The plug-in connection system according to claim 1 or 2, characterized in that: The insulating element is attached to the surface around the through hole in the electrical conductor (3) by the annular flange (14).

4. The plug-in connection system according to claim 3, characterized in that: The insulating element (12) has an inlet ramp (15) below the flange (14) so ​​that the insulating element (12) can be correctly positioned and inserted into the hole in the electrical conductor (3) in a defined manner.

5. The plug-in connection system according to claim 1 or 2, characterized in that: The surface of the port (13) for the screw (6) is designed to be smooth.

6. The plug-in connection system according to claim 1 or 2, characterized in that: An insulating sleeve is adjacent to the annular flange (14) of the insulating element (12), wherein the annular flange (14) and the insulating sleeve are made of the same non-conductive material or different non-conductive materials.

7. The plug-in connection system according to claim 6, characterized in that: The plastic material of the insulating sleeve is polybutylene terephthalate (PBT) or polyether ether ketone (PEEK), and the annular flange (14) is made of PEEK GF20 or ceramic material or anodized metal material.

8. The plug-in connection system according to claim 6, characterized in that: The insulating element (12) is made entirely of unfilled plastic or of plastic with filler, or the insulating element is made of ceramic material or of anodized metal material.

9. The plug-in connection system according to claim 1 or 2, characterized in that: In the end region away from the free end of the screw (6), i.e. in the region of the screw head, there is a cap (8).

10. The plug-in connection system according to claim 9, characterized in that: In order to secure the cover (8), an additional cover (9) is provided on the housing (2).

11. The plug-in connection system according to claim 4, characterized in that: The introduced inclined plane (15) is annular.

12. The plug-in connection system according to claim 4, characterized in that: The electrical conductor is constructed as a conductive rail.

13. The plug-in connection system according to claim 8, characterized in that: The plastic is PEEK GF20 or PEEK GF30.

14. The plug-in connection system according to claim 1 or 2, characterized in that: The contact pair (4) makes contact with the contact pair of the matching plug connector through its annular end face (5).

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