Motor vehicle cable connector

Abstract

The invention relates to a high current cable connector (1) comprising two metal parts (20, 40) and a locking element (60). The metal parts (20, 40) are moved outwardly by the locking element (60) so that two mating surfaces (22, 28, 42, 48) of each metal part (20, 30) are pressed against each other. The orientation of the mating surfaces (22, 28, 42, 48) is such that two further surfaces, contact surfaces (24, 26, 44, 46), of each metal part are also pressed against each other and the cable connector (1) is locked. Thereby a cable connector is obtained which is easy to install, has a low contact resistance and a high heat capacity.

Description

Technical Field

[0001] This invention relates to a cable connector for motor vehicles and a method for manufacturing the cable connector. Background Technology

[0002] With the increasing electrification of automotive travel, ever-increasing currents are being transmitted within vehicles. This is typically achieved through electrical cables. Furthermore, cable connectors are used to connect components such as power electronics, batteries, and motors to cables, as well as to connect first cables to second cables.

[0003] So-called plug-in connectors are widely used. Most known plug-in connectors in the automotive field are based on spring contacts. In this type of spring-resilient plug-in connector, a first and second base, typically made of metal and conducting current, are connected / clamped together by a spring positioned between them. The spring's restoring force achieves a durable mechanical and electrical contact between the spring element and the two bases. These springs, usually very thin, are designed to have numerous point-like protrusions, at least on the contact surface against the base, where mechanical and electrical connections are achieved. At the contact points, current flows between the spring and the base. Due to the limited surface area of ​​such an undulating surface, the contact resistance increases, resulting in Joule heating at the transition. In this design, improvements in current carrying capacity, or reductions in contact resistance and thus power loss, can almost only be achieved by increasing the number of contact points. The choice of spring material in spring-resilient plug-in connectors is always merely a trade-off between conductivity and mechanical properties such as elastic modulus or relaxation.

[0004] In modern vehicles, cables are increasingly used for heat conduction in addition to carrying electrical energy, thanks to the excellent thermal conductivity of their conductor materials such as copper and aluminum. Therefore, cables are now typically a crucial component of thermal management in vehicles. The coupling between two cables, between cables and electrical components, and between electrical components themselves—such as the coupling between battery cell connectors or battery module connectors or to battery cells—so-called flying wire connections, serve not only the task of carrying current but also, consequently, the task of carrying heat. However, such plug-in connectors are unsuitable for this purpose because such transitions in cable harnesses often generate additional unwanted heat due to Joule losses. Furthermore, the typically thin spring components impede heat transfer; more seriously, the small heat capacity of the thin springs due to their structural design can lead to rapid temperature increases, which in the worst case could cause the cable to catch fire.

[0005] Screw connectors are better suited for heat transfer. Here, the force generated by the threads presses the relatively large surfaces of the two base pieces together. This large contact area reduces ohmic resistance and improves thermal conductivity. Similarly, screw connectors typically have a larger thermal mass compared to plug connectors. Therefore, they heat up more slowly than thin springs under high instantaneous current conditions. In this way, they provide a low risk of overheating through the inert thermal characteristics of the connection. This large thermal mass and high thermal conductivity are particularly necessary in the powertrains of electrically driven vehicles, where large current intensities may occur during braking (through energy recovery), acceleration, or high-current charging.

[0006] However, a drawback of spiral connections is that, compared to mating connections, spiral joints involve more time-consuming and error-prone assembly steps. This is particularly problematic given the increasing automation of manufacturing in the electric mobility sector. The increased time consumption of spiral connection assembly makes it unattractive for automated manufacturing. For example, in the manufacture of high-current batteries, where multiple battery cells and modules must contact each other, numerous spiral joints translate to significant assembly costs. Furthermore, problems can arise in spiral connectors due to defective threads or similar issues; therefore, some spiral connectors have adopted contact components with two parallel spiral elements to reduce error variability / error rates. This results in additional assembly costs. Summary of the Invention

[0007] Therefore, the object of this invention is to combine the advantages of spiral connections with those of plug connections. To this end, large areas should be pressed together with high normal force to produce good electrical and thermal conductivity. Furthermore, the connector should have a large heat capacity to absorb a large amount of heat without overheating rapidly. Another concern is installation, which should be quick, repeatable, and as automated as possible.

[0008] This objective is achieved through a connector and a manufacturing method.

[0009] The connector of the present invention comprises a first metal component and a second metal component. The metal components can be made of copper or copper alloys and / or aluminum or aluminum alloys. For example, high-strength aluminum alloys, such as EN AW 6082, can be used. Other materials can also be used, such as other metals or alloys thereof, such as steel, silver, gold, lead, etc., or other conductors, such as polymers, semiconductors, etc. A combination of non-conductors and conductors can also be used, wherein the conductors are arranged at least on the contact surfaces, which will be described later, and the non-conductors perform purely mechanical functions. Combinations of different materials with better and worse conductivity, such as different metals, such as copper and steel, can also be combined. Therefore, compared to a single type of fabrication, good conductivity and high mechanical stability can be achieved on the one hand while reducing costs.

[0010] The two metal parts can be made of the same material, specifically the same metallic material. This has the advantage of eliminating contact corrosion caused by the different redox potentials of the different metals. Another advantage is that there are no different coefficients of thermal expansion. Therefore, the two metal parts expand to the same extent when heated, thus avoiding thermal stress.

[0011] It is also possible that the two metal components are made of different materials and / or combinations of materials, especially two different metallic materials. For example, the first metal component could be made of copper or a copper alloy, and the second metal component could be made of aluminum or an aluminum alloy. Thus, aluminum cables, such as solid flat conductors, and copper conductors, such as flexible stranded conductors, could each be individually connected to a single metal component of the cable connector. This reduces or inhibits contact corrosion between the cable and the connector.

[0012] At least one of the metal components can be made of a solid material. This is advantageous for the heat capacity of the component. Alternatively, at least one of the metal components may include a section of a flat component. In this way and by means of methods, high stability can be achieved with light weight and minimal material usage. Furthermore, the increased surface area facilitates heat radiation and thus enables higher maximum loss conduction in the cable connector. In any case, the size of the metal component can be matched to the wire thickness and / or current intensity, and thus to the expected heat generation and power loss. Larger dimensions result in a larger surface area through which heat can be dissipated and carried away by convection. Moreover, the larger volume results in a higher heat capacity.

[0013] Connecting terminals for conductors may be provided on one or two metal components. These connecting terminals may be circular, flat, or otherwise shaped connecting pieces. The connecting pieces may be configured for brazing or fusion welding of cables, such as friction welding, ultrasonic welding, resistance welding, laser welding, etc. The connecting pieces may be roughened, coated, or otherwise surface-treated. One or more holes may also be provided in the connecting pieces. These connecting terminals may also be formed as sleeves and / or cable connector sleeves. They may be suitable for contacting and / or accommodating flat conductors, round conductors, solid conductors, and / or stranded wires. The connecting terminals are preferably made of the same material as the metal components on which they are mounted. They may also be made of other materials.

[0014] To define the relationships between faces below, we use face normals. First, a face is a continuous region on a three-dimensional body, which can be divided into multiple segments. A face does not have to be flat, but can be composed of segments with different spatial orientations. The orientation of a face segment is characterized by its face normal. A face normal is a vector that is exactly perpendicular to the corresponding face segment. Next, the face normals of the face segments of the body point away from the body, so that the vectors lie outside the body. The length of the face normal vector is unimportant and is set to a normalized value, such as 1 for a selected unit of length. If the dot product of two vectors is less than zero, then the two vectors are described below as opposites to each other. It is permissible, but not necessary, for the two vectors to be exactly antiparallel. When two vectors are perpendicular to each other, their dot product is exactly zero.

[0015] These two metal parts are locally abutting each other. A locking element is provided that causes the two metal parts to move apart. Through the locking element, each metal part moves in a corresponding locking direction. The corresponding locking directions can be represented by vectors. The locking directions of the two metal parts are opposite to each other (see above, a dot product less than zero) and, in particular, can be substantially antiparallel to each other.

[0016] The locking element can be constructed as a locking surface on one of two metal parts, the two metal parts pointing opposite to each other and spaced apart by a gap. By introducing a third element, i.e., a locking member, between the two locking surfaces, the two metal parts can move away from each other. Here, the locking member can be formed as a cuboid, cylinder, or other shape, and in particular, the locking member can taper gradually along a spatial axis. Thus, the locking member can be formed as a wedge. The locking member is preferably inserted into the gap in an insertion direction that is different from the locking direction of the two metal parts. The insertion direction can be oriented substantially perpendicular to the locking direction of at least one of the two metal parts. To better retain the locking member, it can be roughened, for example, by bumps, grooves, slots, rough coatings, etc. At least one of the locking surfaces can also be formed accordingly. It is also possible that the locking element and / or at least one of the locking surfaces is coated, for example, with a non-conductive material such as silicone, rubber, or plastic, which is particularly capable of elastic deformation and thus able to absorb mechanical stress. The locking element and / or at least one of the locking surfaces can also be coated with a conductive coating, such as nickel or tin, which can be softer than the other materials of the locking component.

[0017] The locking component can be at least partially made of a material similar to or the same as one or both of the metal components. This material selection avoids different coefficients of thermal expansion and prevents contact corrosion. Alternatively, the locking component may be formed of a material different from at least one of the metal components, which may be conductive or non-conductive. The locking component can be formed of a solid material. Here, it can be made of a material that can be partially compressed, such as solid copper or aluminum. It is also possible that the locking component is molded from an elastic material such as plastic, rubber, silicone, etc., or from a combination of materials such as rubber-coated glass or ceramic. A locking component made of a solid material can at least partially and precisely fit into the gap between the two locking surfaces, the width of which is set by other connector design options as described below.

[0018] It is also possible that the locking component is not formed from a solid material, but rather has a spring-like elastic structure. For example, it may include a metal clamp. The elastic element, such as the clamp, can absorb mechanical stress as deformation and flexibly insert into the gap between the locking surfaces. No other material needs to be arranged between the elastic elements. However, it is also possible that the locking component includes other components besides the elastic element, such as supporting, conductive, or non-conductive fillers that can be rigid or elastic.

[0019] The locking component can be formed as a separate element, completely separable from the two metal parts. It can also be guided and fixed to one of the two metal parts. Thus, for example, a track can movably support the locking component in essentially one direction. Alternatively, the locking component can be rotatably mounted on one of the metal parts and screwed in to lock. Because the contact of the screwed-in locking component is less likely to dislodge compared to the inserted locking component, it is advantageous, for example, to roughen the surface by grooves. The advantage of a guided locking component is that, in one aspect, the locking component will not be lost if the connection is reopened. Furthermore, it is advantageous in assembly that it is not necessary to keep a stock of individual locking components.

[0020] The metal components are partially abutted against each other. For this purpose, contact surfaces are first provided. Each of the two metal components has a front contact surface located behind the locking element in the locking direction of the metal. Furthermore, each of the two metal components has a second rear contact surface located in front of the locking element in the locking direction. The locking element, or a component of the locking element arranged on the respective metal component, is thus located between the two contact surfaces, one behind and one in front of the metal component. The rear contact surface is spaced apart from the locking element in the opposite direction of the corresponding locking direction of the metal component, while the front contact surface is spaced apart from the locking element in the corresponding locking direction of the metal component. In this case, the locking element refers to a portion of the locking element that is part of the corresponding metal component. For example, this could be the aforementioned locking surface on the corresponding metal component.

[0021] Each of the two metal components has two additional surfaces, namely mating surfaces, in addition to the two front and rear contact surfaces. The first front mating surface is spaced apart from the locking element in the locking direction of the corresponding metal component. The second rear mating surface is spaced apart from the locking element in the opposite direction of the locking direction of the corresponding metal component. Therefore, the front mating surface of each metal component is located on the same side of the locking element along the locking direction as the front contact surface. The rear contact surface and rear mating surface of the same metal component are respectively arranged on the opposite side of the locking element. Here, the front mating surface may be locally farther away from the locking element along the locking direction than the front contact surface. The front mating surface may also be at least locally closer to the locking element than the front contact surface. The same applies to the rear contact surface and the mating surface.

[0022] At least one metal component's front (rear) contact surface and front (rear) mating surface can directly transition into each other, allowing uninterrupted lines to be drawn from the mating surface to the contact surface. Alternatively, the front (rear) contact surface and mating surface can be separate from each other.

[0023] Two metal parts can be shaped to be essentially identical to each other.

[0024] The engagement state of the two metal parts can now be defined. Here, the front contact surface of the first metal part at least partially abuts against the rear contact surface of the second metal part, and the rear contact surface of the first metal part at least partially abuts against the front contact surface of the second metal part. The front mating surface of the first metal part also at least partially abuts against the rear mating surface of the second metal part, and the rear mating surface of the first metal part at least partially abuts against the front mating surface of the second metal part. Here, abutting means that the surfaces can apply forces to each other indirectly or directly. Preferably, mechanical and electrical contact is established between the contact surfaces and / or end faces through abutting. Other elements, such as conductors or non-conductors, may also be arranged between the surfaces. In the case of mating surfaces, such an interlayer may, for example, absorb mechanical stress and / or facilitate sliding between the metal parts. In the case of contact surfaces, such an interlayer may, for example, be a conductive, soft film that compensates for unevenness and establishes good contact. The exemplary interlayer mentioned can also be used on corresponding other surfaces (matting or contact surfaces).

[0025] In any case, large-area contact between the surfaces of two metal parts, especially the contact surfaces, is advantageous for achieving low ohmic resistance and good thermal conductivity.

[0026] In the engaged state, the two metal parts can have substantially closed outer surfaces, which can be described, for example, as cuboids, cylinders, spheres, ellipsoids, wedges, or the like. The precise mating of the two metal parts avoids unwanted edges, thereby reducing the risk of damage to adjacent cables or other components, especially in tight wiring harnesses.

[0027] In the engaged state, the mating surfaces of each metal component serve, on the one hand, to prevent movement of the corresponding other metal component in its locking direction. Thus, when the first metal component moves along its locking direction, at least one of its two mating surfaces, preferably the rearward and the frontward mating surfaces, mates with the front and / or rearward mating surfaces of the second metal component. For this purpose, the mating surfaces of each of the two metal components are oriented at least partially opposite to the locking direction of the corresponding other metal component. Here, reference should be made to the aforementioned definition of "opposite orientation," which describes that the dot product between the surface normal of the mating surface of one metal component and the vector of the locking direction of the corresponding other metal component is negative. "At least partially" should be understood as at least a portion of the surface being oriented accordingly. Because the surface does not necessarily consist of a single flat segment, it can be considered that some areas of the mating surface do not point opposite to the locking direction of the corresponding other metal component, but other areas do. In particular, the areas of the mating surface should be oriented opposite to the locking direction of the corresponding other metal component, which is actually also abutted against these areas in the engaged and / or locked state.

[0028] For each pair of mating surfaces, such as the rear mating surface of one metal component and the front mating surface of another metal component, only one of the mating surfaces can be oriented opposite to the direction of movement of the corresponding other metal component. The corresponding other mating surface can also be formed as a linear, dot-like, or otherwise formed local protrusion. Multiple protrusions can also be considered. The two mating surfaces in a pair can also be oriented planarly and substantially parallel to each other in the locked state.

[0029] As a secondary objective, the force originating from the locking element is at least partially redirected towards the contact surface. To this end, each front contact surface and each front mating surface of a metal component is first defined as "corresponding" to each other, and each rear contact surface and each rear mating surface of the same metal component is defined as "corresponding" to each other. The force redirection is now achieved such that each mating surface not only points locally opposite to the locking direction but also points opposite to the area of ​​its corresponding contact surface. Thus, the contact surfaces also point locally opposite to their corresponding mating surfaces.

[0030] Therefore, the locking element applies force to the contact surface through the mating surface and presses them against each other with a normal force. The front contact surface of the first metal part thus presses against the rear contact surface of the second metal part. The rear contact surface of the first metal part also presses against the front contact surface of the second metal part. Large force is advantageous for ensuring good contact and low contact resistance. As mentioned above, it is advantageous that the two metal parts and the locking element have similar or even identical coefficients of thermal expansion, so that the normal force does not decrease due to different coefficients of thermal expansion within a predictable temperature range of -40°C to 150-180°C.

[0031] As described above, these surfaces, namely the contact surfaces and mating surfaces, do not necessarily have to be completely flat and formed by a single flat segment, but can be formed by multiple segments with different orientations. In particular, the contact surfaces and / or mating surfaces can have undulations. These undulations can be shaped as ribs and grooves, along which one metal component can slide on the other. For example, these undulating structures can be substantially constant along the corresponding locking direction, especially when the locking direction of the metal component extends exactly perpendicular to the surface normal of the undulating contact surface. It is also possible that the contact surfaces and / or mating surfaces are shaped concavely and / or convexly. In an advantageous design, the undulating structures of the two metal components interlock, thereby increasing the size of the contact surface compared to a flat surface on the one hand, and guiding the metal components to each other on the other hand. In particular, for example, each front contact surface can have a concave notch, while each rear contact surface can be embedded in these concave notches using convex shaped portions. Each front contact surface can also have a convex notch, and each rear contact surface is embedded in these convex notches with a concave shaped portion. This also applies to the front and rear mating surfaces. Of course, other surface structures can also be considered, such as serrated, triangular, or toothed undulations.

[0032] In a preferred embodiment, the contact surface of the first metal component is oriented at least partially parallel to the locking direction of the corresponding metal component and / or another metal component. This also applies to the second metal component. The metal components can slide along each other on the contact surface.

[0033] The rear and front contact surfaces of metal parts may be oriented substantially parallel to each other, at least partially, but also entirely. The two contact surfaces of two metal parts may also be oriented at least partially, or even completely, parallel to each other. The same applies to mating surfaces, not only to a single metal part but also to two metal parts.

[0034] Pairs of contact surfaces, formed by the contact surfaces of two separate metal parts, can also be substantially parallel to each other. This applies to the two contact surfaces of a cable connector. The same applies to mating surfaces.

[0035] In a preferred embodiment, the locking directions of the two metal components and the surface normals of the two contact surfaces and the two mating surfaces of the two metal components are at least partially substantially parallel to a common plane or extend parallel to each other.

[0036] The mating surfaces and / or contact surfaces may be coated, at least partially. In particular, they may be provided with a nickel and / or tin coating, which may be softer than the main material of the metal part, thereby producing better contact. The mating surfaces and / or contact surfaces may also be surface-treated in other ways, such as polishing and being manufactured to be particularly flat.

[0037] As an alternative to the locking element consisting of a locking surface and a pushable locking member, other structural forms can be considered. For example, a helical mechanism can be considered, anchored in a thread in one of the two metal parts, and accessible from that thread towards the locking surface of the other metal part. The two metal parts could also have such helical elements that can be moved relative to each other. Clamping or spring elements securely fixed to the metal parts can be envisioned, clamping each other when the two metal parts hook together, thus applying a sustained force and maintaining contact between the metal parts in the engaged state.

[0038] To prevent moisture and other environmental influences, a protective sheath can be provided for the cable connector. This protective sheath may include a coating on the metal components, made of materials such as plastic, silicone, ceramic, rubber, or glass. The coating is preferably applied to the non-contact and / or mating surfaces of the metal components. The coating may also be located in the area of ​​the locking element, but it may also be excluded from the surface of the metal components in that area. To achieve a good seal for the cable connector in the mating state, the coating may laterally protrude from the contact and mating surfaces, preventing gaps through which water and other chemicals can penetrate in the mating state. The protruding edges of the coating may also be provided as grooves on one metal component and as lips on another metal component, so that they interlock when the metal components are engaged. The edges of the coatings on both metal components may also be similarly shaped as, for example, lips, thickened portions, grooves, etc. It is advantageous to select a coating on one metal component that is harder than the coating on the other metal component, so that the edge of the coating on the first metal component can be pressed into the coating on the other metal component, thereby achieving a better seal.

[0039] What may happen is that, for example, if the locking member sinks between the locking surfaces, the locking element leaves an opening in the cable connector. To still achieve insulation against moisture and other environmental influences, a cover can be provided to cover the remaining opening. The locking member itself can also close the opening formed by the two metal elements. For this purpose, the wedge can, for example, have an insulating cover. Closing the opening can establish contact protection, especially against fingers (standard IPxxB) or wires (standard IPxxD), and / or the opening can be waterproof and / or airtight and / or hermetically sealed.

[0040] Alternatively, a housing can be disposed around the entire cable connector, which, in the engaged state, surrounds the cable connector. The housing can be made of silicone, rubber, and preferably a harder material such as plastic or ceramic. Two or more housing components can also be placed and / or fixed to two metal components individually, and they can also be sealed together in the engaged state. Snap-fit ​​elements and / or surrounding seals made of a material softer than the housing, such as silicone or rubber, ensure a durable seal.

[0041] In another embodiment, the metal component may have two additional contact surfaces, two additional mating surfaces, and additional locking elements in addition to the two first contact surfaces, mating surfaces, and first locking elements. The metal component designed in this way can be connected to one, two, or more other metal components, and thus, for example, can achieve a Y-connection. The metal component may also have additional connection surfaces and locking elements, and can achieve 4-way, 5-way, and 6-way connections or links of multiple components and / or cables.

[0042] Metal parts can be manufactured, in particular, by methods such as die casting, precision casting, or extrusion. These methods can achieve exceptionally fine, flat, and uniform surfaces. However, other methods can also be chosen, which, if necessary, are combined with subsequent surface treatments. Attached Figure Description

[0043] The subject matter of the invention will now be explained in detail with the aid of the accompanying drawings, which illustrate embodiments. The drawings show:

[0044] Figures 1a to 1b An embodiment of two metal components of a cable connector according to the present invention is shown;

[0045] Figure 2 An embodiment of a metal component with surface normals drawn according to the present invention is shown;

[0046] Figures 3a to 3g An embodiment of two metal parts according to the invention, hooked together, is shown in a top view;

[0047] Figures 4a to 4b An isometric view of an embodiment of a cable connector according to the present invention is shown;

[0048] Figures 5a to 5c An embodiment of the mating surface of a cable connector according to the present invention is shown;

[0049] Figures 6a to 6f An embodiment of a locking element for a cable connector according to the present invention is shown;

[0050] Figures 7a to 7e An embodiment showing the contours of the mating surface and contact surface of a cable connector according to the present invention is illustrated;

[0051] Figures 8a to 8d An embodiment of an insulated cable connector according to the present invention is shown;

[0052] Figures 9a to 9b An embodiment of a cable connector according to the present invention is shown, the cable connector having a metal component provided for a plurality of contacts;

[0053] Figures 10a to 10d An embodiment of the connection terminals of the cable connector according to the present invention is shown. Detailed Implementation

[0054] The cable connector 1 according to the present invention comprises a first metal component 20 and a second metal component 40. These are... Figure 1a As shown in the figure, the first metal component 20 has a front mating surface 28, a rear mating surface 22, a front contact surface 26, and a rear contact surface 24. Similarly, a second metal component 40 is provided. This second metal component itself has a front mating surface 48, a rear mating surface 42, a front contact surface 46, and a rear contact surface 44.

[0055] Advantageously, the two metal parts 20, 40 are adapted to each other in terms of their external dimensions, especially their thickness, so that a small amount of edge protrusion occurs after joining. It is particularly likely that the two metal parts are shaped substantially identically.

[0056] Figure 1b Two metal components 20 and 40 in a joined state are shown. Here, the front mating surface 28 of the first metal component 20 abuts against the rear mating surface 42 of the second metal component 40, and the rear mating surface 22 of the first metal component 20 abuts against the front mating surface 48 of the second metal component 40. Furthermore, the rear contact surface 24 of the first metal component 20 abuts against the front contact surface 46 of the second metal component 40, and the front contact surface 26 of the first metal component 20 abuts against the rear contact surface 44 of the second metal component 40. Thus, a cuboid is essentially formed.

[0057] The contact of these surfaces with each other can be understood as them exerting forces on each other, at least locally. They can also be indirectly contacted with each other through one or more other elements arranged between the contacting surfaces.

[0058] Two metal parts 20 and 40 move relative to each other via a locking element 60. In the illustrated embodiment, a wedge-shaped element is used as the locking element 66, which moves between two locking surfaces 62 and 64. The first locking surface 62 is on the first metal part 20, and the second locking surface 64 is on the second metal part 40. By inserting the locking element 66, the locking element contacts the two locking surfaces 62 and 64 and pushes these locking surfaces, and thus the metal parts 20 and 40, apart from each other. The locking element 66 can preferably be precisely fitted into the gap such that it presses against the locking surfaces 62 and 64. The locking element 66 can be pressed into the gap between the locking surfaces 62 and 64 with a defined pressure or force.

[0059] The locking member 66 can be defined in a final position in which the two metal parts 20, 40 are fixedly locked to each other and the locking member 66 can only move with effort due to friction on the locking surfaces 62, 64. In this state, the locking member 66 can protrude beyond the surfaces of the metal parts 20, 40, be flush with at least one of the metal parts 20, 40, or form a recess in the cable connector 1.

[0060] The first metal component 20 is moved by the locking element 60 along the first locking direction 50, and the second metal component 40 moves in the second locking direction 52. Here, the locking directions 50 and 52 are different from each other, especially opposite to each other (dot product < 0), and in particular, they can be antiparallel to each other.

[0061] Reference Figure 2 As an explanation, the evaluation of whether two vectors are perpendicular to each other can be performed by shifting the vectors so that they have the same starting point (see...). Figure 2 (The right side portion). For Figure 2 As is evident in the diagram, the surface normal vectors 23 and 29 of the mating surfaces 22 and 28 of the first connecting component 20 are oriented not only in the locking direction 52 of the second metal component 40 but also in the opposite direction to the surface normal vectors 25 and 27 of the contact surfaces 24 and 26.

[0062] This achieves the first metal component 20 preventing the second metal component 40 in the locking direction, because the mating surfaces 42 and 48 of the second metal component 40 abut against the mating surfaces 22 and 28 of the first metal component 20, which point opposite to the locking direction 52 of the second metal component 40. This applies in the completely opposite way to the first metal component 20, which is prevented from continuing to move along its locking direction 50 by the mating surfaces 42 and 48 of the second metal component 40.

[0063] Furthermore, the opposite orientation of the mating surface normals 23, 29 to the corresponding contact surface normals 25, 27 causes the second metal component 40, which moves from the locking element 60 toward the mating surfaces 22, 28, to change direction toward the contact surfaces 24, 26. The second metal component 40 now mates with its corresponding contact surfaces 46, 44 onto these contact surfaces 24, 26, thereby holding the second metal component at least in a force-fit and form-fit manner.

[0064] Figures 3a to 3g Different possible orientations of the contact surfaces 24, 46, 26, 44 and mating surfaces 28, 42, 22, 48 of the two metal parts 20, 40 are shown. Figures 3a to 3g This is a top view of the cable connector 1 of the present invention. The contact surfaces and mating surfaces 24, 46, 26, 44 can here be substantially flat surfaces extending perpendicularly to the drawing plane in a single orientation. They can also be arched, twisted, or otherwise deformed, respectively. For the following purpose, at least one segment of each surface should be oriented substantially perpendicular to the drawing plane, such that... Figures 3a to 3g The seam lines can indicate the local orientation of the surface. The locking directions 50 and 52 of the two metal parts 20 and 40 are in... Figures 3a-3c In the illustrated embodiment, the contact surfaces 24, 26, 44, and 46 are parallel to each other; they are oriented parallel to each other in the engaged state.

[0065] For a more precise explanation of the orientation of the face, please refer to... Figure 2 ,exist Figure 2 The normals 23 (perpendicular to the rear mating surface 22), 25 (perpendicular to the rear contact surface 24), 27 (perpendicular to the front contact surface 26), and 29 (perpendicular to the front mating surface 28) of the first metal component 20 are shown.

[0066] It can be seen that, Figures 3a-3c In all embodiments, the mating surfaces 22, 28, 42, 48 are oriented opposite to the locking direction of the corresponding other metal component (the dot product between the surface normal vectors 23, 25, 27, 29 and the locking direction vectors 50, 52 is < 0).

[0067] It can also be seen that the surface normal vectors 23 and 29 of the mating surfaces 22 and 28 are oriented in opposite directions to the surface normal vectors of their respective contact surfaces.

[0068] exist Figure 3d The diagram illustrates a structural configuration in which contact surfaces 24, 26, 44, and 46 are curved in the top view. They can also be curved to such an extent that the surface normals of their local regions are no longer oriented opposite to the surface normals of their corresponding mating surfaces 22, 28, 42, and 48. It is sufficient that the surface normals of contact surfaces 24, 26, 44, and 46 are locally oriented opposite to the surface normals of their corresponding mating surfaces 22, 28, 42, and 48, respectively.

[0069] exist Figures 3a-3d In some embodiments, the mating surfaces 22, 28, 42, and 48 are generally farther from the locking element 60 than their corresponding contact surfaces 24, 26, 44, and 46. However, the mating surfaces 22, 28, 42, and 48 can also be positioned closer to the locking element 60 than at least a portion of their corresponding contact surfaces 24, 26, 44, and 46, such as... Figure 3e As shown.

[0070] The contact surfaces and mating surfaces 24, 26, 44, 46, 22, 28, 42, and 48 do not typically need to be formed from segments of a single plane, but may also include segments with different orientations. An exemplary embodiment with such surfaces is shown in Figure 3f. Here, mating surfaces 22, 48, 26, and 42 are first divided into sub-regions (22a, 22b, 22c and 48a, 48b, 48c and 28a, 28b, 42a, 42b), each having an orientation according to the invention. The horizontal mating surface regions in the figure have another orientation. In summary, the mating surfaces include these horizontal sub-regions and sub-regions oriented according to the invention (22a, 22b, 22c and 48a, 48b, 48c and 28a, 28b, 42a, 42b). The mating surface 28 is provided with protrusions. Protrusions 28a and 28b can also be considered as mating surfaces 28 themselves. The orientation of their surfaces is not important to the function of the invention. However, at least the smaller raised section is oriented against the locking direction 52 of the second metal member 40 and the surface normal of the corresponding contact surface 26. The orientation of the mating surfaces 42, specifically its sub-regions 42a and 42b, has resulted in the first metal member 20 pressing its contact surface 26 against the contact surface 44 of the second metal member 40. It is evident here that the local orientation of the two contacting mating surfaces 22, 48 and 28, 42 is sufficient to cause the corresponding contact surfaces 24, 46 and 26, 44 to press against each other by means of the locking element 60.

[0071] Figure 3g Another related embodiment is shown, wherein the mating surfaces 22, 48 and 28, 42 are divided into three sub-regions, each having a substantially constant orientation. Here, the horizontally oriented sub-regions (with substantially vertical surface normals) are oriented according to the invention. The vertically oriented sub-regions (with substantially horizontal surface normals) cannot achieve the desired locking on their own. Here, the mating surfaces may also represent only the corresponding horizontally oriented sub-regions, or they may represent surfaces composed of two vertical and one horizontally oriented sub-regions respectively.

[0072] Figures 4a to 4b Two different exemplary embodiments of metal components 20 and 40 are shown. Figure 4aIn this design, both metal components 20 and 40 are formed from multiple flat segments. The contact surfaces 24, 26, 44, 46 and the mating surfaces 22, 28, 42, 48 are also formed from flat segments, which are oriented substantially parallel to the corresponding contact or mating surfaces. To improve mechanical stability, flat elements perpendicular to these segments are provided. These are optional. The advantages of this structural form are reduced material consumption and increased surface area relative to the surrounding environment, through which heat can be dissipated radiatively and otherwise, such as through convection.

[0073] exist Figure 4b Another structural form shown resembles a cylinder. The cylindrical shape facilitates the integration of the cable connector 1 into the wire harness. This is because, for example, particularly for cables with a circular diameter, the connector can be roughly sized to fit the cable diameter. This avoids thickening along the cable harness in the area of ​​the cable connector 1. The lack of sharp edges also reduces the likelihood of damage to adjacent components, especially the cable.

[0074] Figures 5a to 5c Further explanation Figure 3g An embodiment of this embodiment. One of the two mating surfaces in contact may be formed as one or more point-like, line-like, or other shaped protrusions, rather than a surface. The protrusion may be flattened and have an end face oriented substantially parallel to the surface it abuts in the locked state. However, it may also be rounded. Figure 5a The diagram illustrates a rounded structural form. If the protrusion is rounded, only a very small portion of the mating surface 42 is oriented opposite to the locking direction 50 of the first metal member 20 and the surface normal of the contact surface 44. The orientation of the corresponding other mating surface, also formed as a surface, is sufficient to guide the two contact surfaces, respectively corresponding to the mating surfaces, towards each other by a force originating from the locking element 60. A protrusion on one mating surface can, for example, be substantially as follows: Figure 5b A line is drawn in the middle. Here, the protrusion is not as in... Figure 5a Instead of rounded edges, they have flattened end faces. However, rounded shapes can also achieve the same effect. Multiple such linear protrusions, parallel or inclined to each other, are also possible. Alternatively, one can conceive of... Figure 5c The dots are raised in the center. Alternatively, one or more raised surfaces, either ordered or disordered, can also be considered. At least one mating surface can also be heavily roughened to create an irregularly shaped surface structure with protrusions and depressions, which, when locking the cable connector 1 of the present invention, partially contacts and / or presses into and / or penetrates the opposing mating surface of the corresponding other metal component.

[0075] Figures 6a to 6f It shows that, in addition to Figure 1aPossible embodiments of the locking element 60 other than the wedge 66 with locking surfaces 62, 64 disclosed herein.

[0076] In particular, several embodiments of guiding the locking member 66 are disclosed. The guide portion 67 may have the characteristic of allowing the locking member 66 to move only in one direction. Furthermore, the guide portion 67 can connect the locking member 66 to at least one of the metal parts 20, 40 in a loss-proof manner. This has the advantage that only two separate elements, namely the two metal parts 20, 40, are required to assemble the cable connector 1 of the present invention. There is no need to keep the locking member 66 in stock in the processing machinery. Even when the cable connector 1 is opened, there is no risk of the locking member 66 being lost.

[0077] exist Figure 6a The document discloses a wedge-shaped member as a locking member 66, which is movable along a guide 67. The guide 67 may include a track or other substantially linear protrusion in the locking surface 62, which is surrounded by a groove or other substantially linear notch in the locking member 66. The guide may also be provided as a notch in the locking surface 62 of the metal member 20 (or the locking surface 64 of the metal member 40) and protruding on the locking member 66.

[0078] Another example of a locking element 60 with guide 67 is... Figure 6b As shown in the diagram. Here, the locking member 66 is rotatable about the guide portion 67, which is formed as a rotary bearing. By moving the locking member 66 from... Figure 6b The cable connector 1 is locked by screwing it from the position shown above to the position shown below. Here, the rounded shape of the locking member 66 is advantageous so that the locking member 66 can move fully within the gap to the position shown below. Figure 6b The final position is shown in the lower part.

[0079] In the two locking element configurations shown, and in other locking element configurations, increasing the friction between the locking member 66 and the locking surfaces 62, 64 may be useful. This can be achieved by surface roughening, through sandblasting, etching, and other methods, or also by targeted undulations, such as those created during casting by means of grooves, bumps, corrugations, etc., which can increase the friction between the locking member 66 and the locking surfaces 62, 64. Figure 6c An example is shown of a roughened surface.

[0080] Alternate locking element 60 Figures 6d-6f As shown in [the image]. Figure 6d In this configuration, the locking element 60 includes a bolt guided in the threads of the first metal member 20, which is rotatable against the locking surface 64 of the second metal member 40. In this case, the locking member 66 is a bolt.

[0081] Figure 6e A spring element is shown as a locking member 66, which is fixedly or movably mounted on the locking surface 62 of the first metal member 20 and is pressed in when the two metal members 20, 40 are assembled, such that the restoring force of the spring element causes the two metal members 20, 40 to move away from each other.

[0082] and Figure 6e similar, Figure 6f Another spring element is shown. Figure 6d The spring element in the design has the advantage that lateral insertion does not cause the spring to deflect significantly downwards, and the spring can also compress the metal part in the locking direction after insertion. Figure 6f The spring may also require another guide in the spring direction. A common advantage of the spring element as the locking member 66 is that the two metal parts 20, 40 can be inserted together and locked immediately. However, a disadvantage is that the force emanating from the locking element 60 is significantly reduced compared to, for example, a metal wedge that engages under pressure. Therefore, the normal force on the mating and contact surfaces is reduced, and the resistance at the contact points may become higher.

[0083] As previously discussed, the contact surfaces 24, 26, 44, 46 and the mating surfaces 22, 28, 42, 48, as well as the locking surfaces 62, 64, do not need to be flat with a single orientation, but can be regions with different orientations. Some examples of this surface shape are... Figures 7a to 7e The diagram shows undulations, as visible through cross-sections of the two metal parts 20 and 40. Advantageously, the faces of the metal parts 20 and 40 are capable of sliding along each other in a preferred direction. This is ensured for the contact surfaces by ensuring that the profile in a direction perpendicular to the locking direction of the metal parts is constant along the locking direction of at least one of the metal parts. For example, grooves may appear in the metal along this direction. For the mating surfaces 22, 28, 42, and 48, a constant undulation in the direction toward the corresponding contact surface is helpful so that the metal parts slide onto the contact surfaces along this profile. Figure 7a The advantageous profile direction with an exemplary angular contour is shown.

[0084] Furthermore, it is beneficial for the metal parts 20 and 40 to engage with each other at the contact and mating surfaces. In this way, the metal parts 20 and 40 are reliably guided. Moreover, they are better held on each other in the locked state, and the contact surface is increased compared to flat contact and mating surfaces. The aforementioned contouring is particularly advantageous for the contact surfaces.

[0085] Figure 7b The outline of the first wave shape is shown. Figure 7c The concave profile of the first surface and the convex profile of the second surface, which is its complement, are shown. Figure 7d Another embodiment of the interlocking surfaces is shown.

[0086] To improve the contact between the mating surfaces, they can be coated, especially with softer metals such as nickel or tin. Other metals such as gold or other conductive materials can also be considered. The coating is advantageously applied only to the areas of the contacting and mating surfaces; see [reference needed]. Figure 7e The cladding layers are 70 and 72.

[0087] The cable connectors 1 described to date typically also have an unprotected metallic outer surface. The disadvantage is that they may come into electrical and mechanical contact with other conductors, and are also susceptible to corrosion or other damage due to environmental influences. To eliminate these risks, it is advantageous to externally isolate the cable connector 1 of the present invention. This can be achieved by a housing placed around the cable connector 1 after connection and locking.

[0088] Figure 8a Another advantageous embodiment of insulation against the surrounding environment is shown. Here, at least some portions of the outer surfaces of the metal components 20, 40 are coated with an insulating layer 80, which are not contact surfaces, mating surfaces, locking surfaces, or other outer surfaces that do not require insulation. This insulating layer is preferably non-conductive and can be made of plastic, silicone, rubber, but can also be made of ceramic, glass, etc.

[0089] To achieve complete insulation of the metal parts 20, 40 of the cable connector 1 in the locked state, an opening in the area of ​​the locking element 60 can be closed with a cover 82 after locking. The cover 82 can also be part of a locking member 66, which, for example, has an insulating closure that blocks the opening when pushed in. The cover can also be formed as part of the housing. The head of the wedge can also be insulatingly coated. The wedge can also be formed as part of the housing.

[0090] There is an increased risk of moisture intrusion in the transition area between the insulation layer 80 and the contact surface and / or mating surface, which must be in direct electrical and mechanical contact with each other. To avoid this, the insulation layer 80 may protrude from the surface, as in... Figure 8c , 8d As shown in the diagram, the groove 84 in the extended portion of the insulating layer 80 on one metal component and the corresponding protrusion 86 on the insulating layer 80 of the other metal component, which engages with the groove, enable improved insulation performance in the transition between the two metal components 20, 40. Multiple grooves 84 and lips 86 can also be provided, arranged side-by-side and interlocking with each other, thereby improving the sealing effect.

[0091] In addition, such as Figure 8d As shown, the insulating layers 80a and 80b of the first metal component 20 can be softer than the insulating layers 80c and 80d of the second metal component 40. Because the excess portions of the harder insulating layers 80c and 80d can be pressed into the softer insulating layers 80a and 80b, the insulation is particularly tight.

[0092] The cable connector 1 of the present invention, as described herein, is designed for connecting two cables or other components. The connection scheme can also be extended to multiple cables. Figures 9a to 9b A cable connector 1 according to the present invention is shown, wherein a second metal part 40 has a plurality of mating portions for the cable connector 1, the plurality of mating portions respectively including a front mating surface 48, a front contact surface 46, a rear contact surface 44, and a rear mating surface 42. At least a portion of a locking element 60 is also provided. Figure 9a It shows a star-shaped structural form. Figure 9b It shows a structural form arranged side by side.

[0093] To connect cable connector 1 to the cable, a connector is required. Therefore, Figures 10a to 10d Some embodiments of the cable connection terminal 90 are shown. Therefore, in Figure 10a The paper discloses a connector with holes. This can be used for threaded connections or riveting. Figure 10b A flat terminal 90 without holes is shown, for example, for crimp or solder connections. Figure 10c A circular terminal 90 is shown. This can be formed as a solid material. Cables can be welded here, for example, especially by means of friction welding, ultrasonic welding, and / or laser welding. It is also possible to consider... Figure 10d The hollow structure shown is that of sleeve 90, which can serve as a cable connector sleeve to accommodate cables or other components. Sleeve 90 may also have a circular cross-section.

Claims

1. A cable connector for motor vehicles, comprising: First metal component The second metal component is attached to the first metal component. A locking element that causes two metal parts to move away from each other in corresponding locking directions, wherein, The locking element includes a first locking surface on the first metal component and a second locking surface on the second metal component, the first locking surface and the second locking surface pointing in opposite directions and spaced apart. The locking element further includes a locking component located between the two locking surfaces and capable of displacing the two locking surfaces from each other. in, Each of the two metal components has a front mating surface and a corresponding front contact surface that are away from the locking element in the locking direction of the respective metal component, and a rear mating surface and a corresponding rear contact surface that are away from the locking element in the opposite direction of the locking direction of the respective metal component. In the locked state of the cable connector, the front mating surface of each of the two metal parts abuts against the rear mating surface of the corresponding other metal part, and the front contact surface of each of the two metal parts abuts against the rear contact surface of the corresponding other metal part. Its features are, The surface normals of the front and rear mating surfaces of a metal component extend at least partially opposite to the locking direction of the corresponding other metal component, wherein the surface normals extending opposite to the locking direction indicate that the dot product of the surface normals and the locking direction is less than zero. For each of the two metal parts, the surface normal of the front contact surface extends at least locally in the opposite direction to at least a portion of the surface normal of the corresponding front contact surface, and For each of the two metal parts, the surface normal of the rear contact surface extends at least locally in the opposite direction to at least a portion of the surface normal of the corresponding rear contact surface, wherein the surface normal in the opposite direction indicates that the dot product of the surface normals is less than zero.

2. The cable connector for motor vehicles according to claim 1, Its features are, The front contact surface of at least one of the two metal components is at least partially and substantially in direct contact with the rear contact surface of the corresponding other metal component on a width perpendicular to the locking direction, and the surface profiles of the two contact surfaces are substantially constant along the locking direction of at least one of the two metal components.

3. The cable connector for motor vehicles according to claim 1, Its features are, The locking element includes a first locking surface on the first metal component and a second locking surface on the second metal component, the first locking surface and the second locking surface being oriented opposite to each other and spaced apart by a gap, and a locking wedge abutting against the two locking surfaces such that the locking wedge pushes the two metal components apart from each other in their respective locking directions.

4. The cable connector for motor vehicles according to claim 1, Its features are, The two metal parts are shaped essentially the same way.

5. The cable connector for motor vehicles according to claim 1, Its features are, The front and rear mating surfaces of the two metal parts, the local surface normals of the front and rear contact surfaces, and the locking direction of the two metal parts extend substantially parallel to a common plane.

6. The cable connector for motor vehicles according to claim 1 or 2, Its features are, The surface normals of the front and / or rear contact surfaces of at least one of the two metal components are oriented at least locally and substantially in the same direction.

7. The cable connector for motor vehicles according to claim 1, Its features are, The surface normals of the front and rear mating surfaces of at least one of the two metal parts are oriented at least locally and substantially in the same direction.

8. The cable connector for motor vehicles according to claim 1, Its features are, The locking direction of the first metal component is oriented substantially opposite to the locking direction of the second metal component, wherein the opposite orientation of the locking directions indicates that the dot product of the locking directions is less than zero.

9. The cable connector for motor vehicles according to claim 8, Its features are, The locking directions of the two metal parts are opposite to each other.

10. The cable connector for motor vehicles according to claim 1, Its features are, The front mating surface of at least one of the two metal parts is at least partially concave, and / or the rear mating surface of the corresponding other metal part is at least partially convex, or the front mating surface of at least one of the two metal parts is at least partially convex, and / or the rear mating surface of the corresponding other metal part is at least partially concave.

11. The cable connector for motor vehicles according to claim 1, Its features are, One of the two metal parts has a localized protrusion on its front mating surface.

12. The cable connector for motor vehicles according to claim 11, Its features are, The protrusions are either dot-shaped or line-shaped.

13. The cable connector for motor vehicles according to claim 1, Its features are, At least one of the two metal components has a front contact surface that is at least partially concave and a rear contact surface that is at least partially convex, or at least one of the two metal components has a front contact surface that is at least partially convex and a rear contact surface that is at least partially concave.

14. The cable connector for motor vehicles according to claim 1, Its features are, At least one of the contact or mating surfaces of at least one metal component has a conductive coating.

15. The cable connector for motor vehicles according to claim 14, Its features are, The conductive coating is a nickel coating, a silver coating, a gold coating, or a copper coating.

16. The cable connector for motor vehicles according to claim 1, Its features are, At least one mating surface of at least one metal component is indirectly abutted against the mating surface of another metal component, and a conductor or non-conductor is provided between the mating surfaces, and / or at least one contact surface of at least one metal component is indirectly abutted against the contact surface of the other metal component, and a conductor is provided between the contact surfaces.

17. The cable connector for motor vehicles according to claim 1, Its features are, At least one of the two metal components is covered with an insulating layer on the surface of at least one non-contact or non-butting surface.

18. The cable connector for motor vehicles according to claim 1, Its features are, The insulating layer of at least one of the two metal parts protrudes beyond at least one contact surface and / or mating surface, and / or the insulating layer of the first metal part is joined to the insulating layer of the second metal part in the engaged state.

19. The cable connector for motor vehicles according to claim 18, Its features are, The insulation layers of the two metal parts are at least partially or circumferentially waterproof and tightly bonded to each other.

20. The cable connector for motor vehicles according to claim 1, Its features are, The cover is placed over the locking element in the locked state.

21. The cable connector for motor vehicles according to claim 20, Its features are, The cover provides contact protection for the cable connector and / or makes the cable connector waterproof to the outside.

22. The cable connector for motor vehicles according to claim 1, Its features are, The locking element is a helical element, a spring element, and / or a wedge.

23. The cable connector for motor vehicles according to claim 1, Its features are, At least one of the metal components has a connecting bracket.

24. The cable connector for motor vehicles according to claim 23, Its features are, The connection bracket is a plug and / or a socket.

25. The cable connector for motor vehicles according to claim 1, Its features are, The first metal component is made of a first metal material and the second metal component is made of a second metal material, wherein the first metal material is different from the second metal material or the first metal material is the same as the second metal material.

26. The cable connector for motor vehicles according to claim 1, Its features are, At least one of the metal components is formed at least partially as a flat part and / or at least one of the metal components is formed at least partially as a solid material.

27. The cable connector for motor vehicles according to claim 1, Its features are, The two metal components are substantially complementary in the locked state to be cuboids, cylinders, spheres, ellipsoids, or wedges.

28. The cable connector for motor vehicles according to claim 1, Its features are, At least the first metal component has at least two additional contact surfaces and two additional mating surfaces, an additional metal component is capable of engaging the at least two additional contact surfaces and two additional mating surfaces, and at least a second locking element locks the first metal component to the second metal component.

29. A method for manufacturing a cable connector according to claim 1, wherein, At least one of the two metal parts and / or one of the locking parts is manufactured by die casting, precision casting and / or extrusion methods.

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