Plug connector assembly and plug connection

Abstract

The invention relates to a plug connector assembly (1) having a plug connector (2) and a plurality of electrical conductors (3). The plug connector (2) has a plug connector housing (4) into which an axial end region (32) of each electrical conductor (3) is inserted and fixed. On each electrical conductor (3) or on each contact element (31) connected as one with each electrical conductor (3) a respective contact surface (27) is formed, which is designed to make electrical contact with a counter contact surface (26) of a corresponding counter contact element (22) of a counter plug connector (19). Each contact surface (27) has a respective directional component in a first direction, which is perpendicular to the longitudinal axial direction of the respective electrical conductor. The plug connector housing (4) is provided for each electrical conductor (3) with at least one respective spring element (15), which is connected with the respective electrical conductor (3) and is designed to press the contact surface (27) against the counter contact surface (26), which has a directional component in the first direction, which is perpendicular to the longitudinal axial direction of the respective electrical conductor. According to the invention, each contact surface (27) has a directional component in a second direction, which is perpendicular to the longitudinal axial direction of the respective electrical conductor (3) and to the first orthogonal direction. The plug connector housing (4) is provided with a fixing element (11), which is designed to press each electrical conductor (3) or the contact surface (27) of each contact element (31) against the counter contact surface (26) of the corresponding counter contact element (22) in the second perpendicular direction, which also has a directional component in the longitudinal axial direction of the corresponding counter contact element (22) when the fixing element is connected with a fixing element (28) of the counter plug connector (19).

Description

[0001] This application claims priority to European Patent Application No. 21169675.2, the contents of which are incorporated herein by reference in their entirety. TECHNICAL FIELD

[0002] The present application relates to a plug connector assembly and a plug connection. BACKGROUND

[0003] The plug connection is used for transmitting data signals and supply currents. The electrical contact between the contact element of the plug connector and the counter contact element of the associated counter plug connector, especially in the case of plug connections with high currents and high voltages, is influenced by a contact strip arranged between them, which can generate sufficient contact pressure between the contact element and the counter contact element.

[0004] For example, DE 10 2013 217 256 B3 discloses a plug connection with a plug-in contact element and a contact sleeve, and with a separate contact strip between the two. Such a plug connection is used, for example, in the charging path between a charging interface and a battery, in the traction path between a battery and an electric drive, or in the high-voltage path between a battery and other electrical devices in an electric or hybrid vehicle.

[0005] The contact element and the counter contact element generate two contact transitions through the inserted contact sleeve, which increases the transmission impedance on the transmission path between the plug connector and the counter plug connector. In particular in the case of the use of aluminum as a contact material, the contact surfaces of the individual contact parts oxidize over time, which also influences the transmission impedance in the transmission path. The increasing currents or voltages in electric or hybrid vehicles, especially in the charging path, greatly limit the development of this trend, as the increasing transmission impedance in the transmission path.

[0006] This situation should be improved.

[0007] In terms of technical background, reference is also made to the following documents. EP 2 690 716 A1 relates to an electrical connection element comprising a basic body having at least one connection portion and at least one socket portion having at least one contact arm for contacting a plug contact which can be inserted into the socket portion, wherein the contact arm is divided into at least two partial contacts in a contact region in which the contact of the plug contact introduced takes place. Furthermore, the electrical connection element comprises a spring which surrounds the basic body in the region of the socket portion and has at least one spring arm which interacts with the contact arm at least in the contact region, so that the contact arm can be deflected against the restoring force of the spring arm. WO 2011 / 053276 A1 relates to a socket connector, the design of which can improve the pin contact engagement or holding force. FR 2 794 293 A1 relates to a contact element which can be inserted into a cylindrical conductor. Finally, DE 20 2018 104 493 U1 relates to a spring with stabilizing function for an electrical connection socket. SUMMARY

[0008] Against this background, it is the object of the present application to provide a plug connector, in particular for the transmission of larger currents or higher voltages, which has a minimum transmission resistance between the contact elements and the associated counter contact elements.

[0009] According to the application, a plug connector assembly achieves this object.

[0010] Accordingly, there is provided:

[0011] A plug connector assembly having

[0012] - a plug connector and

[0013] - a plurality of electrical conductors,

[0014] - wherein the plug connector has a plug connector housing,

[0015] - wherein the axial end region of each electrical conductor is inserted and fixed,

[0016] - wherein, at each electrical conductor or

[0017] At each contact element, which in each case is connected in one piece to the respective electrical conductor, in each case

[0018] - a contact surface is formed

[0019] - which is configured to be in electrical contact with a counter contact surface of an associated counter contact element of a counter plug connector,

[0020] - wherein, in each case, the respective contact surface has a directional component in a first direction perpendicular to the longitudinal axis of the respective electrical conductor,

[0021] - wherein, in each case, at least one spring element is arranged in the plug connector housing for each electrical conductor,

[0022] - which, in each case, is connected to the respective electrical conductor, and

[0023] - is configured to press the contact surface against the counter contact surface, which has a directional component in a direction perpendicular to the longitudinal axis of the respective counter contact element and a directional component in a first direction perpendicular to the longitudinal axis of the respective electrical conductor.

[0024] The insight / idea on which the present application is based is to minimize the number of contact transitions in the plug connection:

[0025] To this end, on the one hand, direct contact is achieved between the contact partners of the plug connector and the counter plug connector without the need for an intervening contact sleeve with contact strips. On the other hand, the contact surfaces belonging to the contact partners of the plug connector are either formed directly in the individual electrical conductors or in contact elements which are formed integrally with the individual electrical conductors.

[0026] In order to exert sufficient contact pressure between the two contact partners, i.e. between the individual contact surface in the plug connector and the associated counter contact surface in the counter plug connector, at least one spring element is provided in each case for each electrical conductor inserted into the plug connector, which, in each case, presses the electrical conductor and the contact surface belonging to the electrical conductor against the associated counter contact surface in the counter plug connector. The electrical conductor is thus arranged between the spring element and the associated counter contact element.

[0027] In order to minimize the structural space of the plug connection, the electrical conductor and the associated counter contact element need to be arranged opposite one another in a direction which, in each case, is perpendicular to the longitudinal axis of the electrical conductor and also perpendicular to the longitudinal axis of the engaging contact partner in the plugged state of the plug connection. The longitudinal axis of the electrical conductor and the associated counter contact element are thus spaced apart laterally from one another, i.e. arranged opposite one another in the direction of the lateral extent of the electrical conductor and the associated counter contact element. It is noted in this connection that the longitudinal extent or longitudinal axis of a body refers to the greatest extent or direction of greatest extent of the body, while the lateral extent refers to the lesser extent of the body.

[0028] Accordingly, the contact surface of each electrical conductor or of each contact element which is connected as a unit with the respective electrical conductor has a directional component which is perpendicular to the longitudinal axis of the electrical conductor or of the counter contact element. Accordingly, each spring element which is connected with an electrical conductor presses the contact surface of the electrical conductor or of the contact element which is connected as a unit with the electrical conductor against the counter contact surface of the associated counter contact element in a first direction which is perpendicular to the longitudinal axis of the electrical conductor.

[0029] During operation, a constant and sufficient force is applied in each case by the individual spring elements from the contact surface to the associated counter contact surface in the first direction which is perpendicular to the longitudinal axis of the electrical conductor. The design of the contact surface is such that it complements the counter contact surface so that the entire surface is in contact with the associated counter contact surface without air. This effectively prevents oxidation or corrosion of the contact surface and the counter contact surface. It is thus also possible to avoid an influence on the transmission impedance due to surface oxidation of the contact surface or of the counter contact surface over the operating time.

[0030] In addition, due to the permanent force application of the at least one spring element, it is also possible to prevent time-dependent contact fatigue, so-called contact relaxation, of the contact area of the electrical conductor or of the contact element which is connected as a unit with the electrical conductor.

[0031] The plug connector assembly is preferably a plug connector assembly for transmitting large currents or high voltages. Large currents in this context and in the following mean transmission currents of an electric or hybrid vehicle, typically between 300 A and 600 A. The high voltages transmitted in electric or hybrid vehicles are preferably in the range of 450 V to 1500 V, in particular 750 V to 1000 V.

[0032] The electrical conductor is preferably designed as a flat electrical conductor. A flat electrical conductor is understood in this context and in the following as an electrical conductor which has a first lateral extent and a second lateral extent, wherein the first lateral extent is larger, preferably significantly larger, than the second lateral extent. The surface formed by the first lateral extent and the longitudinal extent of the flat electrical conductor is preferably of flat design. The first lateral extent of the flat electrical conductor is preferably oriented perpendicular to the second lateral extent, so that a rectangular cross-sectional profile is achieved.

[0033] Depending on the application, the flat electrical conductor can be configured as a busbar, i.e. a rigid flat electrical conductor, or as a cable, the strands of which are pressed against each other at the axial ends. In the latter case, the flat electrical conductor has a rigid design in at least one axial end region. Finally, the flat electrical conductor can also have a certain bending flexibility due to its dimensions and the materials used, in order to be able to be flexibly mounted on the body of an electric or hybrid vehicle.

[0034] It is preferred that two electrical conductors for the transmission of direct current or alternating current are inserted into the plug connector assembly. However, it is also possible to use three electrical conductors for the transmission of three-phase current or a plurality of pairs of (integer) electrical conductors for the transmission of a plurality of direct current and / or alternating current.

[0035] The individual electrical conductors are preferably fixed in the plug connector housing of the plug connector assembly in a form-fit manner by means of the individual electrical conductors (with a certain longitudinal cross-section of suitable shape) and the associated passage in the plug connector housing (with matching shape). However, it is also possible to force the individual electrical conductors into the plug connector housing or to fix them by means of material bonding.

[0036] The plug connector housing consists of one part or of a plurality of parts, preferably of two parts, and has an opening through which the electrical conductors are inserted. In order to bring the electrical conductors into contact with the associated mating contact elements, the plug connector housing also has a further opening through which the mating contact elements of the mating plug connector can be inserted into a common receiving chamber in the plug connector housing or, in each case, into an individual receiving chamber.

[0037] The plug connector housing can be embodied in a suitable form in order to achieve the technical functions of fastening, fixing, sealing, etc. according to the state of the art. Finally, the housing of the plug connector needs to be made of a suitable dielectric material and has a suitable size in order to meet the requirements for the dielectric strength of the air gap and the creepage path at high currents and high voltages.

[0038] The electrical conductors and the contact elements connected thereto are preferably made of a metal material which has a good electrical conductivity, a high wear resistance and, at the same time, a low specific density. Aluminum or copper is preferably used. Silver is preferably used as a coating material in order to improve the contact resistance.

[0039] The electrical conductors and the associated contact elements are preferably connected in one piece by means of material bonding, for example by means of welding or soldering.

[0040] Advantageous embodiments and developments can be found in the description below with reference to the drawings.

[0041] It is to be understood that the features mentioned above and those to be explained below can be used not only in the respective specified combinations, but also in other combinations or in isolation, without departing from the scope of the present application.

[0042] According to the application, the contact surface has, in addition to a directional component in a first direction perpendicular to the longitudinal axis of the electrical conductor, also a directional component in a second direction perpendicular to the longitudinal axis of the electrical conductor and to the first perpendicular direction. The mating contact surface of the associated mating contact element thus has, in addition to a directional component perpendicular to the longitudinal axis of the mating contact element, also a directional component parallel to the longitudinal axis of the mating contact element.

[0043] Furthermore, a fastening element is arranged in the plug connector housing, which, together with a corresponding fastening element in the mating plug connector, fastens the plug connector to the mating plug connector. The fastening element of the plug connector and the complementary fastening element of the mating plug connector generate sufficient contact pressure between the contact surfaces and the associated mating contact surfaces in the direction of the longitudinal axis of the mating contact element.

[0044] In this case, a normal force acts in each case from a single contact surface of the plug connector onto the associated mating contact surface of the mating plug connector, which has a directional component in each case in the direction of the longitudinal axis of the mating plug connector, but also a directional component perpendicular to the direction of the longitudinal axis of the mating contact element.

[0045] Due to the directional component of the respective single contact surface and the associated mating contact surface in the direction of the longitudinal axis of the mating contact element and the component perpendicular to the direction of the longitudinal axis of the mating contact element, a relative movement between the single contact surface and the associated mating contact surface occurs along the contact surface and the mating contact surface during the plug-in process. This manifests itself as a frictional movement (sliding friction) of the contact surface on the associated mating contact surface, preferably in connection with the wear of the oxide layer on the contact surface and the mating contact surface. In the plugged-in state of the plug connector and the mating plug connector, the contact force acting in the plug-in direction, which the fastening element has to exert, is greatly reduced due to the presence of static friction.

[0046] The respective contact surface and the associated mating contact surface have a directional component in the direction of the longitudinal axis of the mating contact element and a directional component transverse to the direction of the longitudinal axis of the mating contact element, which can be planar or convex in shape. For convex or curved shapes, this can be a one-way or two-way convexity or concavity. The contact surfaces of the planar contact surfaces and the mating contact surfaces have the same orientation. The curvature of the convex contact surfaces and the mating contact surfaces is identical.

[0047] A preferred embodiment of the fastening element is a fastening screw. In its longitudinal extent, i.e. on the screw axis, the fastening screw coincides with the longitudinal axis of the mating contact element and can be screwed into a screw sleeve of the mating plug connector. The internal thread of the screw sleeve corresponds to the external thread of the fastening screw. The screw sleeve thus represents the fastening means of the mating plug connector and the mating fastening means of the fastening element. The fastening screw can be inserted into the plug connector housing via a passage formed in the plug connector housing, which passage is aligned in the direction of the longitudinal axis of the mating contact element. The advantage of the screw connection for fastening is that sufficiently high fastening forces and contact forces can be achieved, which result in a secure fastening and contact.

[0048] The latching connection can also serve as a fastening between the plug connector and the mating plug connector instead of a screw connection. To this end, latching means, such as latching hooks, latching tabs, latching lugs, spring arms, snap hooks, etc., can be formed on the plug connector housing, and associated mating latching means, such as latching recesses, snap recesses, etc., can be formed on the mating plug connector housing. In order to exert sufficient contact pressure between the respective contact surfaces and the associated mating contact surfaces in the longitudinal axial direction of the mating contact elements, in the case of a latching connection, an additional spring element is required in each case for each electrical conductor, which is connected to the respective electrical conductor and presses the respective contact surface against the associated mating contact surface in the longitudinal axial direction of the mating contact elements. Therefore, on the side of the plug connector housing opposite the contact surfaces of the electrical conductors, additional spring elements are required which exert a spring force on the electrical conductors in the longitudinal axial direction of the mating contact elements.

[0049] Likewise, on the side of the plug connector housing opposite the contact surfaces of the electrical conductors, spring elements are required which exert a spring force on the electrical conductors in a direction transverse to the longitudinal axial direction of the mating contact elements.

[0050] By arranging the spring elements outside the contact region, the number of contact transitions can be minimized, thus reducing the transfer impedance of the contact region, while at the same time contact pressure is built up between the two contact elements. In order to exert contact pressure between the two contact elements and thus transfer the spring force from the spring elements to the electrical conductors, the spring elements need to be placed in a pre-tensioned state between the plug connector housing and the electrical conductors.

[0051] The shape of the spring elements is preferably a spring tab on a metal sheet, preferably a metal sheet. This design is advantageous for forming a plurality of spring tabs on a metal sheet. The installation of a plurality of spring tabs on a metal sheet to the electrical conductors is particularly advantageous in the case of electrical conductors having a plurality of parallel contact surfaces and / or in the case of a conductor cross-section having a flat geometry, for example in the case of flat electrical conductors. Thus, a metal sheet with individual spring tabs can be arranged parallel to the flat electrical conductors between the plug connector housing and the flat electrical conductors, thus parallel to the individual parallel contact surfaces. In this way, it is ensured in each case that the force from the individual spring tabs to the individual contact surfaces of the electrical conductors is transferred parallel and equally in a direction transverse to the longitudinal axis of the mating contact elements.

[0052] The spring elements can take any other spring form, such as a helical spring or an elastic element, instead of a spring tab punched and bent from a metal sheet.

[0053] Since the contact surfaces and the counter contact surfaces in each case have a directional component in the longitudinal axial direction of the counter contact element and a directional component transverse to the longitudinal axial direction of the counter contact element, a plurality of alternative contact embodiments are possible when the longitudinal axes of the electrical conductors and the associated counter contact elements are arranged transversely spaced apart in the plugged state of the plug connector and the counter plug connector, as follows. It is noted here that the longitudinal axes of the electrical conductors and the counter contact elements are not only transversely spaced apart from one another, but are preferably also perpendicular to one another.

[0054] In a first variant of this contact, the electrical conductors need to be deformed in the axial end region transversely to the longitudinal axis, so that in the deformed region a contact surface is formed which has a directional component not only in the longitudinal axis direction of the counter contact element, but also in the direction transverse to the longitudinal axis direction of the counter contact element.

[0055] If the first transverse extent of the flat electrical conductor is large and parallel to the longitudinal axis of the counter contact element, the electrical conductor needs to be deformed, preferably stamped and bent, in a first direction perpendicular to the longitudinal axis of the electrical conductor, i.e. in the direction of the second, smaller transverse extent, in order to form such a contact surface in the axial end region of the electrical conductor.

[0056] For flat electrical conductors positioned and oriented in this way relative to the counter contact element, this deformation can be, for example, a strip- or tab-like region protruding from the flat electrical conductor, which is deformed by stamping and bending. The strip-like region is connected to both ends of the flat electrical conductor, while the tab-like region is connected to only one end of the flat electrical conductor.

[0057] In a second variant of the contact, the electrical conductors are connected as a whole in the axial end region to a contact element on which the contact surface is formed, which has a directional component in the longitudinal axial direction of the counter contact element and a directional component transverse to the longitudinal axial direction of the counter contact element. The contact element can be connected transversely to the longitudinal axis of the electrical conductor or to the front end of the electrical conductor. In both cases, the contact element must extend from the electrical conductor in the longitudinal axis direction of the counter contact element to be contacted, in order to achieve contact with the counter contact element.

[0058] For example, this formation on the contact element can be strip-like, tab-like, rib-like or lug-like.

[0059] In a third contact variant, the electrical conductors are shaped relative to the edge on one side of the longitudinal axis of the electrical conductor, so that the shaped side edge of the electrical conductor forms the contact surface. The shape of the side surface of the electrical conductor is complementary to the counter contact surface of the associated counter contact element. The shaping of the side surface as a contact surface is related to various aspects of the surface profile, such as its direction, curvature, etc.

[0060] In the case of a flat electrical conductor, the side surface that serves as the contact surface according to the third variant is preferably the smaller side surface. Here, the smaller second lateral extent of the flat electrical conductor is parallel to the longitudinal axis of the mating contact element.

[0061] In this orientation of the flat conductor relative to the longitudinal axis of the mating contact element, a contact surface can also be formed on the deformed region of the conductor. Finally, contact elements with sheet-like, rib-like, or lug-like shapes can also be mounted on the smaller side surface of the axial end region of the flat conductor.

[0062] To transmit direct current (DC) or alternating current (AC), two electrical conductors are inserted in parallel into the plug connector. These conductors, in the plug state, contact two mating contact elements arranged in parallel within the connector. Because the longitudinal axes of the two conductors are arranged laterally relative to the longitudinal axis of the respective mating contact element in each case, the two parallel conductors can surround the two mating contact elements, allowing them to be spaced closer or further apart in the intermediate region between the two mating contact elements. To transmit multiple DC or AC currents, each individual pair of conductors and its associated mating contact element needs to be arranged in parallel.

[0063] To enhance the current-carrying capacity between the electrical conductor and its associated mating contact elements, multiple parallel contact surfaces are formed on the electrical conductor, each capable of contacting a corresponding mating contact surface on the mating contact element. For example, the parallel contact surfaces may be formed in one of multiple regions that are deformed parallel to each other on the electrical conductor.

[0064] Alternatively, the parallel contact surfaces can be formed separately on a common contact element that is integrally connected to the electrical conductor. Finally, in each case, each parallel contact surface can also be formed on a separate contact element that is integrally connected to the electrical conductor.

[0065] Since the contact surface and its associated mating contact surface cannot necessarily have exactly the same flatness, and also cannot have exactly the same flatness relative to each other, this affects the transmission impedance. Therefore, in a preferred extension of the contact system, a single contact surface is decomposed into multiple parts. This technique increases the number of contact points between the contact surface and the mating contact surface, thereby improving the transmission impedance. If a region of the contact surface of the electrical conductor is deformed into a strip or sheet shape, the number of contact points can be increased by slotting the deformed strip or sheet shape. If the rib-shaped, ear-shaped, or sheet-shaped contact area of ​​the contact element is integrated with the electrical conductor, the number of contact points can also be increased by slotting the rib-shaped, ear-shaped, or sheet-shaped contact area.

[0066] In another preferred embodiment of the invention, each contact surface has a structured surface, preferably a grooved surface. The structured surface of the contact surface may also have a microstructure consisting of pointed protrusions, sharp teeth, or sharp ridges. The structured surface of the contact surface has a negligible effect on the transmission impedance, but it can destroy the oxide layer on the mating contact surface during the mating process. Furthermore, the mating contact surfaces may each have a structured surface for destroying the oxide layer on the relevant contact surface.

[0067] Because the spring force of the specified spring element potentially acts on the electrical conductor, over time, coupled with material fatigue of the dielectric material of the mating plug connector housing, the associated mating contact elements may experience undesirable displacement or tilting. To ensure mechanical stability of the contact system, a clamping element needs to be inserted into a channel formed in the longitudinal axial direction of the mating contact element within the plug connector housing, and into a groove formed on the mating plug connector housing, flush with the channel. The clamping element is inserted into the groove of the mating plug connector housing such that the clamping element is force-fitted with the area near the groove of the mating plug connector housing, preferably by pressure fit.

[0068] Due to the pressure fit between the clamping element and the mating plug connector housing, material fatigue would occur in a certain area of ​​the mating plug connector housing without the clamping element. In this area, material compaction and thus increased material strength are advantageous. Therefore, displacement or tilting of the mating contact element can be effectively avoided, thereby preventing an increase in transmission impedance and, in extreme cases, preventing contact loss between the electrical conductor and the associated mating contact element.

[0069] The clamping element is preferably made of a dielectric material. In a preferred arrangement of the contact elements, two mating contact elements are arranged between two electrical conductors, and the clamping element is arranged in a groove between the two mating contact elements within the mating plug connector. In the plug connector's inserted state, the clamping element, containing the fastening screw and associated screw sleeve, has a sleeve-shaped area.

[0070] To achieve a clamping effect, the clamping element has at least two jaws, which are formed radially outward from the sleeve-shaped region of the clamping element in two opposite directions. These two jaws are respectively mounted in the grooves between the two mating contact elements to prevent displacement or tilting of the mating contact elements. To improve the mechanical stability of the clamping element within the mating plug connector, four jaws are formed on the clamping element, each jaw forming radially outward from the sleeve-shaped region, with the four directions perpendicular to each other. Two additional jaws are fixed in the grooves between the two contact areas of the two mating contact elements.

[0071] In another arrangement of the contact elements, two electrical conductors are positioned between two mating contact elements. Preferably, there are two clamping elements, each force-fitted into a groove between its respective mating contact element and the outer wall of the mating plug connector housing. The two clamping elements are suitable for connection with fastening elements, particularly with fastening screws.

[0072] In each case, each clamping element can be connected to the plug connector housing, preferably in a fixed manner, such as by a latching connection. Furthermore, each clamping element forming the dielectric is connected to a fastening element, particularly a metal fastening screw. For this purpose, it is preferable to equip a metal sleeve, which is screwed to the metal fastening screw and then pressure-fitted to the dielectric clamping element.

[0073] The present invention also includes a plug connector. The plug connector has a plug connector assembly, a plug connector, and a mating plug connector corresponding to the plug connector. A contact surface formed on each electrical conductor of the plug connector assembly, or a contact surface formed on each contact element of the plug connector assembly, here contacts a corresponding mating contact surface, which in each case is formed on the associated mating contact element.

[0074] The features of the plug connector assembly described above also apply to plug connectors.

[0075] Finally, the present invention relates to a method for providing electrical connection via a plug connector, the plug connector comprising a plug connector and a mating plug connector. The high-voltage electrical transmission configuration between the plug connector and the mating plug connector includes at least the following method steps:

[0076] a) Connect multiple electrical conductors of the plug connector to the relevant mating contact elements of the mating plug connector;

[0077] b) Electrical plug connection between the plug connector housing of the locking plug connector and the mating plug connector housing of the mating plug connector.

[0078] Where meaningful, the above-described embodiments and development results can be combined with each other in any desired manner. Other possible embodiments, modifications, and implementations of the invention include combinations of features of the invention not explicitly mentioned, which have been described in the exemplary embodiments above or below. In particular, those skilled in the art can also add individual aspects as improvements or supplements to the basic forms of the invention. Attached Figure Description

[0079] The present invention will now be described in detail with reference to the exemplary embodiments shown in the accompanying drawings:

[0080] FIG. 1A and FIG. 1B An exploded view of a plug connector assembly and a mating plug connector designed according to the present invention is shown.

[0081] FIG. 2A and FIG. 2B The longitudinal cross-sectional view and plan view show the first manifestation of the contact.

[0082] FIG. 3A and FIG. 3B The longitudinal cross-sectional view and plan view of the second manifestation of the contact are shown.

[0083] FIG. 4A and FIG. 4B The longitudinal cross-sectional view and plan view show the third manifestation of the contact.

[0084] FIG. 5A and FIG. 5B The longitudinal cross-sectional view and plan view show the fourth manifestation of contact.

[0085] FIG. 6A and FIG. 6B The longitudinal cross-sectional view and plan view show the fifth manifestation of the contact.

[0086] FIG. 7A , FIG. 7B , FIG. 7C , FIG. 7D The diagram shows a plan view, a longitudinal sectional view, and first and second sectional views of the plug connector assembly according to the invention in the unplugged state.

[0087] FIG. 7E , FIG. 7F , FIG. 7G , FIG. 7H The diagram shows a plan view, a longitudinal sectional view, and first and second sectional views of a plug connector designed according to the present invention.

[0088] FIG. 7I , FIG. 7J , FIG. 7K The diagram shows a cross-sectional view of the mating plug connector in the unplugged state, as well as first and second longitudinal section views.

[0089] The accompanying drawings are intended to aid in a further understanding of embodiments of the invention. They illustrate examples of the invention and, together with the description, explain the principles and concepts of the invention. Other embodiments and many of the mentioned advantages can also be found with reference to the drawings. Elements in the drawings are not necessarily shown to scale.

[0090] Unless otherwise expressly stated, the same reference numerals shall be used for the same elements, features and components, and elements, features and components having the same function and role, in every case.

[0091] These figures will be described in a coherent and comprehensive manner below. Detailed Implementation

[0092] The following will be based on FIG. 1A The exploded diagram explains the structure of the plug connector assembly, and according to... FIG. 1B The exploded diagram explains the structure of the related matching plug connectors:

[0093] The plug connector assembly 1 includes a plug connector 2 and two electrical conductors 3. Since the two electrical conductors 3 are not only connecting elements for connecting electrical devices or other plug connectors, but also electrical contacts of the plug connector 2, they can also be understood as components of the plug connector 2. The plug connector 2 has a plug connector housing 4. The two electrical conductors 3 are preferably designed as flat electrical conductors, allowing them to be inserted into the plug connector housing 4 through a side opening 5. The opening 5 of the plug connector housing 4 can be... FIG. 1A The housing cover, which is not shown in the diagram but belongs to the plug connector housing 4, is closed.

[0094] Furthermore, a channel 6 is formed in the plug connector housing 4 to insert a clamping element 7, the channel being transverse to the longitudinal axis of the electrical conductor 3. The clamping element 7 is secured to the plug connector housing 4 by a latching element 8 and an associated mating latching element (formed on the inner wall of the channel 6). The clamping element 7 has a channel 9. The helical shaft of the fastening screw 11 is inserted through a first end 10 of the channel 9 and extends from a second end of the channel 9 for tightening the threaded sleeve of the mating plug connector. To secure the metal fastening screw 11 in the insulated channel 9 of the clamping element 7, a metal sleeve 12 is pressed into the channel 9 of the clamping element 7 at the first end 10. The fastening screw 11 is secured to the metal sleeve 12 by a threaded connection between the internal thread of the metal sleeve 12 and the external thread of the fastening screw 11.

[0095] Each electrical conductor 3 has multiple strip-shaped regions 13, which serve as contact areas for the electrical conductor 3. For example, FIG. 1A The conductor 3 shown has two strip-shaped regions 13 in each case. To increase the number of contact points, as... FIG. 1A As shown, the strip-shaped independent region 13 also has additional slots. Two electrical conductors 3 are inserted into the plug connector 2 through the transverse opening 5 together with the associated metal plate 14, which has multiple spring elements in the form of spring sheets 15.

[0096] exist FIG. 1AIn the variant of the plug connector 2 shown, two metal plates 14 with shaped spring tabs 15 are arranged between the outer wall 16 of the plug connector housing 4 and the electrical conductor 3, so that the associated spring tabs 15 press the electrical conductor 3 against the inner wall 17 of the plug connector housing 4. For this purpose, the shape of the inner wall 17 matches the shape of the electrical conductor 3 and the strip-shaped region 13. The electrical conductor 3 is designed as a flat electrical conductor, each with a longitudinal cross section 18, for example, in the shape of an "S", which is pressed against the correspondingly shaped inner wall 17 of the plug connector housing 4 by the housing cover. In this way, the electrical conductor 3 can be fixed to the plug connector housing 4 in a shape-fitting manner.

[0097] according to FIG. 1B The mating plug connector 19 has a mating plug connector housing 20 with an opening 21 through which two mating contact elements 22 are inserted into corresponding fixing areas 23 formed in the mating plug connector housing 20. Each mating contact element 22 has a certain number of mating contact areas 24, the number of which corresponds to the number of contact areas (i.e., the number of deformable areas 13) of the electrical conductor 3. The two mating contact areas 24 and the connection engagement area 25 form a U-shaped mating contact element 22.

[0098] A mating contact surface 26 is formed at the axial ends of two mating contact regions 24, the longitudinal extent of which is pin-shaped and rectangular in cross-section. Each mating contact surface 26 of the mating contact element 22 has a corresponding surface profile relative to an associated contact surface 27, which is formed in the contact region of the associated electrical conductor 3. Therefore, each contact surface 27 of each electrical conductor 3 and each individual mating contact surface 26 of each mating contact element 22 has, in each case, a directional component that is either aligned with or opposite to the longitudinal axis direction of the mating contact element 22, and a directional component that is perpendicular to the longitudinal axis direction of the mating contact element 22.

[0099] The metal threaded insert 28 has an internal thread that is complementary to the external thread of the fastening screw 11 and is inserted as a fastening element of the mating plug connector 19 through the opening 21 of the mating plug connector housing 20 into the associated fixing area 29 formed in the mating plug connector housing 20.

[0100] When the plug connector 2 and the mating plug connector 19 are plugged in, contact can occur between the contact surfaces 27 of the two electrical conductors 3 and the corresponding mating contact surfaces 26 of the mating contact elements 22. To enable contact surface 27 to contact the corresponding mating contact surfaces 26 of the mating contact elements 22, contact surface 27 is accessible relative to the corresponding mating contact surfaces 26, and contact surface 27 is formed on the electrical conductors 3 and the contact elements 31 integrally connected to the electrical conductors 3. For this purpose, the plug connector housing 4 also...FIG. 1A The rear and lower regions have openings.

[0101] According to FIG. 7A to FIG. 7K Various views and cross-sections are described in detail below regarding the various forms of contact of the plug connector assembly 1, associated plug connector 2, and associated mating plug connector 19 according to the present invention, before the un-molded state and the mated state:

[0102] exist FIG. 2A and FIG. 2B The diagram clearly shows a first manifestation of the contact between two electrical conductors 3 and two associated mating contact elements 22, wherein the mating contact elements 22 are arranged between the two electrical conductors 3 in the plug connector 30 in the plugged-in state. In each case, the two electrical conductors 3 are flat electrical conductors, wherein the larger lateral extent of the flat electrical conductors is parallel to the longitudinal axis of the mating contact elements 22.

[0103] Thus, the strip-shaped region 13 of the conductor 3 will face the direction of the fastening screw 11. Therefore, each contact surface 27 of the conductor has a directional component in the longitudinal axis of the mating contact element 22, particularly in the direction of the mating plug connector 19, and in the direction perpendicular to the longitudinal axis of the mating contact element 22, i.e., in the direction of the fastening screw. The spring plate 15 of the metal plate 14 is located outside the conductor 3, pressing the contact surface 27 of the conductor 3 transversely to the longitudinal axis of the mating contact element 22, against the corresponding mating contact surface 26 of the mating contact element 22. The fastening screw 11, screwed into the corresponding threaded sleeve 28, presses the plug connector housing 4 against the mating plug connector housing 20, thereby pressing the contact surface 27 of the conductor 3 against the mating contact surface 26 of the mating contact element 22 in the longitudinal axis direction of the mating contact element 22.

[0104] exist FIG. 3A and FIG. 3B In the second form of contact shown, the electrical conductor 3 is located between associated mating contact elements 22. Therefore, the metal plate 14 and the associated spring sheet 15 are arranged inside the electrical conductor 3, pressing the outwardly deformed strip-shaped region 13 and the contact surface 27 formed thereon against the mating contact surface 26 of the associated mating contact element 22.

[0105] exist FIG. 4A and FIG. 4B In the third form of contact shown, the contact area of ​​the electrical conductor 3 faces inward along the direction of the fastening screw 11. Unlike the first form of contact, the contact surface is not formed in the electrical conductor 3, but is realized at the contact element in each case. The contact element is shaped as a rib, lug, strip, or sheet and is integrally connected to the associated electrical conductor 3, preferably bonded together with a material.

[0106] exist FIG. 5A and FIG. 5B In the fourth form of contact shown, unlike the first three contact methods, the direction of the larger lateral range of the conductor 3, which is designed as a flat electrical conductor, is perpendicular to the longitudinal axis of the mating contact element 22 in each case.

[0107] In each case, the contact surface 27 of a single conductor 3 is formed on the side surface 44 of the conductor 3, that is, the side surface 44 of the conductor 3 with a smaller lateral range, which is arranged transversely to the longitudinal axis of the conductor 3. The shape of the side surface 44 of the conductor 3 in each case is such that it has a directional component on the longitudinal axis of the mating contact element 22 and a directional component in a direction perpendicular to the longitudinal axis of the mating contact element 22.

[0108] exist FIG. 6A and FIG. 6B In the fifth embodiment of the contact shown, the larger lateral extent of the flat conductor is also perpendicular to the longitudinal axis of the mating contact element 22. In this fifth embodiment, the axial end region 32 of the conductor 3 is reshaped to form a deformed region 13 in each case of the axial end region 32 of the conductor 3. This deformed region 13 has a contact surface 27 having a directional component in the longitudinal axis direction of the mating contact element 22 and a directional component in the direction perpendicular to the longitudinal axis of the mating contact element 22.

[0109] In each case, the deformation of the axial end region 32 of the electrical conductor 3 is achieved through stamping and bending processes. This is done to obtain more contact points, such as... FIG. 6B As shown, the deformable region 13 can also be shaped to be slotted. Furthermore, the fifth form of contact can be improved by realizing the deformable region 13 through a contact element 31 of a corresponding shape, which is integrally connected to the axial end region 32 of the individual electrical conductor 3, for example by material bonding.

[0110] The plug connector assembly 1, plug connector 2, mating plug connector 19, and plug connector 30 will be described below. FIG. 7A to FIG. 7K According to FIG. 2A and FIG. 2B The first manifestation of the contact shown is described in detail:

[0111] according to FIG. 7A , FIG. 7B , FIG. 7C and FIG. 7D As shown in the present invention, when the plug connector assembly 1 is not plugged in, two electrical conductors 3 are inserted into the plug connector housing 4 of the plug connector 2, each of which is a flat electrical conductor. FIG. 7BAs shown, the longitudinal portion 18 of each conductor 3 is S-shaped and supported on the corresponding protruding inner wall 17 of the plug connector housing 4 in a form-fitting manner. In order to fix each conductor 3 in the plug connector housing 4, a housing cover (not shown for clarity) is installed in the side opening 5 of the plug connector housing 4. The housing cover is fixed to the plug connector housing 4 and presses the two conductors against the inner wall 17 of the plug connector housing 4.

[0112] For example, two strip-shaped regions 13 are formed in the axial end region 32 of each conductor 3. In each case, these two regions 13 have multiple contact points for contacting the associated mating contact element 22 in multiple slots. Each strip-shaped region 13 of the conductor 3 has a contact surface 27, which has a directional component aligned with the longitudinal axis of the mating contact element 22 and a directional component perpendicular to the longitudinal axis of the mating contact element 22.

[0113] Each electrical conductor 3 is pressed against the correspondingly shaped inner wall 17 of the plug connector housing 4 in the axial end region 32 by the spring force of multiple spring tabs 15, which deforms into a strip shape. A single spring tab 15 is formed on a metal plate 14 located between the outer wall 16 of the plug connector housing 4 and the axial end region 32 of the single electrical conductor 3.

[0114] In order for the contact surface 27 of the conductor 3 to contact the mating contact surface 26 of the corresponding mating contact element 22, the plug connector housing 4 of the plug connector 2 is provided with a receiving cavity for receiving the mating contact element 22 in the area of ​​the contact surface 27 (see...). FIG. 7C and FIG. 7D ).

[0115] Clamping element 7 in the direction of mating plug connector 19 (see) FIG. 7C and FIG. 7D The connector is inserted into channel 6, which is formed in the plug connector housing 4, particularly in the inner wall 17 of the plug connector housing 4.

[0116] The clamping element 7 extends from the channel 6 of the plug connector housing 4 and enters the groove 34, which is formed in the mating plug connector housing 20 and flush with the channel 6 of the plug connector housing 4. The clamping element 7 is inserted into the groove 34 when the fastening screw 11 is secured in the threaded sleeve 28. For this purpose, the clamping element 7 is connected to the fastening screw 11. The fastening screw 11 is located at the center of the clamping element 7. Therefore, the clamping element 7 has a sleeve-shaped region 35 in which the fastening screw 11 is mounted.

[0117] Inside the sleeve-shaped region 35 of the clamping element 7, a sleeve-shaped fastening portion 36 with a channel 9 is formed. This portion connects to the sleeve-shaped region 35 of the clamping element 7 for the passage and fastening of the fastening screw 11. To secure the metal fastening screw 11 to the dielectric fastening portion 36 of the clamping element 7, a metal sleeve 12 is pressed into the sleeve-shaped fastening portion 36 of the clamping element 7 and connected to the fastening screw 11 by a threaded connection. The screw head 37 of the fastening screw rests against the flange 38 of the metal sleeve 12. The flange 38 of the metal sleeve 12 rests against the end face 39 of the clamping element 7, and the flange 40 of the clamping element 7 rests against the end face 41 of the plug connector housing 4.

[0118] To clamp the clamping element 7 and the mating plug connector housing 20 within the groove 34 of the mating plug connector housing 20, it is preferable to form four jaws 42 on the clamping element 7. These four jaws 42 extend radially outward from the sleeve-shaped region 35 of the clamping element 7 in a cross shape. The jaws 42 in the clamping element 7 are cross-shaped, and each jaw 42 has a certain degree of elasticity, so it can be pressed into the cross-shaped groove 34 in the mating plug connector housing 20.

[0119] A cross-shaped groove 34 is formed between a fixing region 23 and a fixing region 29 within the mating plug connector housing 20. The fixing region 23 is used for mating contact elements 22, and the fixing region 29 is used for threaded sleeves 28.

[0120] FIG. 7I , FIG. 7J and FIG. 7K A mating plug connector 19 with a mating plug connector housing 20 is shown. Two mating contact elements 22 are arranged within the housing 20, each having two mating contact areas 24. Each mating contact element 22 is U-shaped, and the two mating contact areas 24 are interconnected via a connection area 25. Each mating contact element 22 is fixed in a corresponding fixing area 23 formed within the mating plug connector housing 20. A metal threaded sleeve 28 is mounted in another fixing area 29, which is centrally located relative to the other fixing areas 23 within the mating plug connector housing 20.

[0121] FIG. 7E , FIG. 7F , FIG. 7G and FIG. 7H The plug connector 30 represents the plug connector 2 and the mating plug connector 19 in the inserted state, respectively:

[0122] The fastening screw 11 is screwed into the threaded sleeve 28 to fix the plug connector 2 and the mating plug connector 19 relative to each other. The mating contact element 22 of the mating plug connector 19 is inserted into the receiving cavity 33 within the plug connector housing 4. In each case, the contact surface 27 in the deformable region 13 of the two electrical conductors 3 contacts the mating contact surface 26 in the mating contact area 24 of the mating contact element 22.

[0123] Although the present invention has been fully described above with reference to preferred exemplary embodiments, the present invention is not limited thereto, but can be modified in a variety of different ways.

Claims

1. A plug connector assembly (1) having a plug connector (2) and a plurality of electrical conductors (3), wherein the plug connector (2) has a plug connector housing (4), and an axial end region (32) of each electrical conductor (3) is inserted into and fixed in the plug connector housing (4), wherein, A contact surface (27) is formed at each electrical conductor (3) or at each contact element (31) in each case, the contact element (31) being integrally connected to the corresponding electrical conductor (3) in each case, the contact surface (27) being configured to make electrical contact with the mating contact surface (26) of the associated mating contact element (22) of the mating plug connector (19), wherein the corresponding contact surface (27) has a directional component in a first direction perpendicular to the longitudinal axial direction of the corresponding electrical conductor in each case, wherein at least one spring element (15) is provided for each electrical conductor (3) within the plug connector housing (4) in each case, the spring element (15) being connected to the corresponding electrical conductor (3) in each case and configured to press the contact surface (27) against the mating contact surface (26), the mating contact surface (26) having a directional component perpendicular to the longitudinal axial direction of the corresponding mating contact element in a first direction perpendicular to the longitudinal axial direction of the corresponding electrical conductor. Its features are, The corresponding contact surfaces additionally have directional components in a longitudinal axial direction perpendicular to the electrical conductor (3) and in a second direction perpendicular to the first direction. A fastening element (11) is arranged in the plug connector housing (4), the fastening element (11) being configured to press the contact surface (27) of each electrical conductor (3) or each contact element (31) against the mating contact surface (26) of the associated mating contact element (22) in a second vertical direction when connected with the fastening element (28) of the mating plug connector (19), the mating contact surface having an additional directional component in the longitudinal axial direction of the corresponding mating contact element (22).

2. The plug connector assembly (1) according to claim 1. Its features are, The fastening element in the plug connector housing (4) is designed as a fastening screw (11), while the fastening element of the matching plug connector (19) is designed as a threaded sleeve (28).

3. The plug connector assembly (1) according to claim 1 or 2. Its features are, In each case, the spring element (15) is arranged on one side of the electrical conductor (3) inside the plug connector housing (4), opposite to the side of the electrical conductor (3) that forms the contact surface (27).

4. The plug connector assembly (1) according to claim 1 or 2. Its features are, The spring element connected to the electrical conductor (3) is in the shape of a spring sheet (15) in the metal plate (14) in every case.

5. The plug connector assembly (1) according to claim 1 or 2. Its features are, In each case, each electrical conductor (3) is configured such that the longitudinal axis of the electrical conductor, in the plug connector (2) and mating plug connector (19) plugged in, is laterally spaced from the longitudinal axis of the associated mating contact element (22).

6. The plug connector assembly (1) according to claim 5. Its features are, In each case, each conductor (3) is laterally deformed relative to the longitudinal axis of the corresponding conductor (3) so that the corresponding contact surface (27) is formed in the deformed region (13) of the corresponding conductor (3), or in each case, each contact element (31) is laterally shaped relative to the longitudinal axis of the corresponding conductor (3) so that the corresponding contact surface (27) is formed in the corresponding contact element (31).

7. The plug connector assembly (1) according to claim 6. Its features are, The deformation region (13) of the electrical conductor (3) is deformed into a strip or sheet in each case, and the contact element (31) is shaped into a strip, sheet, rib or lug in each case.

8. The plug connector assembly (1) according to claim 5. Its features are, In each case, a side surface (44) is formed on each electrical conductor (3) to form a corresponding contact surface (27) on the side surface (44), wherein the side surface (44) is arranged transversely to the longitudinal axis of the corresponding electrical conductor (3).

9. The plug connector assembly (1) according to claim 1 or 2. Its features are, In each case, multiple contact surfaces (27) are formed on each electrical conductor (3), or in each case, on a contact element (31) connected to each electrical conductor (3), or, in each case, contact surfaces (27) are formed on multiple contact elements (31) connected to each electrical conductor (3), wherein each contact surface (27) is configured to make electrical contact with an associated mating contact surface (26) of an associated mating contact element (22).

10. The plug connector assembly (1) according to claim 1 or 2. Its features are, In each case, each contact surface (27) has a structured surface.

11. The plug connector assembly (1) according to claim 1 or 2. Its features are, In each case, each contact surface (27) has a slotted surface.

12. The plug connector assembly (1) according to claim 1 or 2. Its features are, In each case, the clamping element (7) is inserted into at least one channel (6) formed in the plug connector housing (4) in the direction of the mating plug connector (19), and the clamping element (7) is configured to be able to be inserted into an associated recess (34) formed in the mating plug connector housing (20), the recess (34) being flush with the corresponding channel (6), and thus the clamping element (7) being able to be connected to the mating plug connector housing (20) in a force-fit manner.

13. The plug connector assembly (1) according to claim 12. Its features are, The corresponding clamping element (7) is connected to the fastening element, wherein the fastening element is configured to press the corresponding clamping element (7) into the associated groove (34) of the mating plug connector housing (20) when connected to the fastening element of the mating plug connector (19).

14. The plug connector assembly (1) according to claim 1 or 2. Its features are, The electrical conductor (3) is a flat electrical conductor.

15. The plug connector assembly (1) according to claim 1 or 2. Its features are, The electrical conductor (3) is designed to transmit current in the range of 300A to 600A.

16. A plug connector (30) having a plug connector assembly (1) according to any one of claims 1 to 15 and a mating plug connector (19) corresponding to the plug connector (2), wherein, In each case, the contact surface (27) formed on each electrical conductor (3) and the contact surface (27) formed on each contact element (31) are in electrical contact with the mating contact surface (26) formed on the mating contact element (22) associated with the mating plug connector (19).

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