Connector with removable inlet protection element

Abstract

An electrical plug connector may include a plug insert (130) and pin contacts (150) disposed within the plug insert (130). The protection level of the electrical plug connector may be IP20'finger safety '. Finger safety is achieved by a contact tip insulator (160) which can be fastened to a front end of the pin contact (150) and a removable access protection frame (170) which comprises an access barrier (176) arranged between a side wall (132) of the plug insert (130) and the pin contact (150).

Description

Technical Field

[0001] The present disclosure relates to electrical connectors and more particularly to industrial plug connectors with an insertion side protection rating of IP20. Background Art

[0002] Plug and socket connectors usually consist of a male plug and a female socket. The plug usually includes pin contacts, and the socket usually includes socket contacts. As in the chassis connector, the socket is usually permanently fixed to the device, while the plug is attached to the cable. Both the plug and the socket can be connected to a cable to, for example, connect two cables together.

[0003] A plug typically has one or more metal contacts, also called terminals, that insert into openings in a mating receptacle. The connection between the mating metal parts must be tight enough to make a good electrical connection and complete the circuit.

[0004] IEC 60529 has been developed to rate and classify the protection against intrusion of dust and liquids by enclosures of electrical and electronic equipment, and to rate the ease with which potentially hazardous parts within the enclosure can be accessed by a person.

[0005] IP20 is often referred to as the "finger-safe" rating for electrical components in the IEC 60529 rating system. It refers to the fact that a probe approximately the size of a finger must not approach or touch hazardous live parts. Live parts that may be easily accessible when resetting, adjusting or replacing nearby components must be protected against direct contact with a degree of protection of at least IP20. Summary of the invention

[0006] Traditionally, the insertion side of plug connectors has not met the "finger-safe" requirement of IP20. In contrast, electrical socket connectors are designed to be finger-safe, while plug connectors are designed not to contain any energized pin contacts when disconnected from their mating sockets. Therefore, finger safety is generally not required for plug connectors.

[0007] In some applications, it may be desirable for an electrical plug connector to meet IP20 "finger safe" requirements. Thus, even if the plug connector is disconnected from its mating receptacle, the pin contacts may still be energized. This may be caused, for example, by a residual charge of a capacitor electrically connected to the pin contacts of the plug connector.

[0008] An IP20 rated electrical plug connector includes a plug insert. A pin contact is disposed within the plug insert. A contact tip insulator is secured to a front end of the pin contact. A plurality of contact retaining arms extend from a side wall of the plug insert toward the pin contact for securing the pin contact in the plug insert. A removable inlet protection frame includes an inlet barrier disposed between the side wall and the pin contact and in front of the contact retaining arms.

[0009] When the inlet protection frame is removed from the connector for servicing, the width of the access opening between the side wall and the contact tip insulator is greater than 12 mm. Without the contact tip insulator and the inlet protection frame, the plug connector is not finger safe. When the contact tip insulator and the inlet protection frame are installed, the width of the remaining access opening between the side wall and the contact tip insulator is less than 12 mm, at which point the plug connector is finger safe.

[0010] The inlet protection frame may include a base plate. The base plate may include a central contact opening. A plurality of retaining arms may extend forwardly from the base plate. The retaining arms may each include a chamfered protrusion extending outwardly near a front end thereof. The retaining arms and their chamfered protrusions snap into place with the window of the plug insert. The inlet barrier may extend forwardly from the base plate between the retaining arms. The inlet barrier is typically cubic.

[0011] The following detailed description is merely exemplary in nature and is not intended to limit the invention or the application and uses of the invention. In addition, the present invention is not limited to any theory presented in the foregoing background or the following detailed description. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Figure 1 An exploded view of a plug and receptacle connection system is shown.

[0013] Figure 2 A plug housing and a similar receptacle housing are shown which are configured to be connected to a corresponding cable.

[0014] Figure 3 An example of a plug insert is shown.

[0015] Figure 4 yes Figure 3 Section IV-IV of the plug insert shown.

[0016] Figure 5 yes Figure 3 VV section of the plug insert shown.

[0017] Figure 6 is a perspective rear view of the inlet protection frame.

[0018] Figure 7 Yes Figure 6 A perspective front view of an inlet protection frame is shown. DETAILED DESCRIPTION

[0019] Figure 1 An exploded view of a plug and socket connection system is shown. The system comprises a plug connector 100 and a socket connector 200.

[0020] The plug connector 100 includes a plurality of pin contacts 150. Pin contacts are sometimes also referred to as male contacts. In the context of this application, they should be more broadly understood to refer to first type contacts. When in use, each pin contact 150 is electrically connected to a conductor of a cable. The contacts can be in the form of screw terminals, crimp terminals or cage clamp terminals. The terms "contact" and "terminal" can be used interchangeably. The pin contacts 150 are firmly held in the plug insert 130. The plug insert 130 is in turn fixed in the plug housing 110. The plug housing 110 can also be called a cover. The plug housing 110 includes a cable entry opening 105, which can be configured to allow the cable to enter from the rear or from the side. The cable entry protection device 120 can be fixed to the cable entry opening 105. The cable entry protection device 120 can have a variety of configurations. The cable entry protection device 120 can be, for example, a universal cable connector, a special cable clamp with strain protection, a bell-mouth cable fitting or an anti-twist device. The cable connector can include one or more seals.

[0021] The plug connector 100 is configured to mate with a corresponding socket connector 200. The socket connector 200 includes a plurality of socket contacts 250. Socket contacts are sometimes referred to as female contacts. In the context of this application, they should be more broadly understood as second type contacts. Each socket contact 250 is configured to accommodate a pin contact 150 to establish an electrical connection. The socket contact 250 is securely held in a socket insert 230. The socket insert 230 is fixed in a socket housing 210.

[0022] The geometric shapes of the plug insert 130 and the socket insert 230 match so that they can be plugged together. When plugged together, the plug insert 130 and the socket insert 230 partially overlap.

[0023] A locking mechanism may be provided to lock the plug connector 100 with the receptacle connector 200. The locking mechanism may include a lever 211 pivotally connected to the receptacle housing 210. The lever 211 may include a groove that engages with a locking protrusion 111 of the plug housing 110. When engaged, the lever securely holds the plug connector 100 and the receptacle connector 200 together. The lever 211 may be pivoted to an unlocked position to disengage the locking protrusion 111, thereby removing the plug connector 100 from the receptacle connector 200.

[0024] Figure 1 An example is shown in which the receptacle connector 200 is adapted to be permanently fixed to the device as in a chassis connector. Figure 2 Another configuration is shown, in which the plug housing 110 and the socket housing 210 are similar and are both configured to be connected to a corresponding cable. The plug housing 110 and the socket housing 210 both include corresponding cable entry openings 105, 205. The plug housing 110 is locked with the socket housing 210 by a locking mechanism. The locking mechanism here includes two levers 211, 212. The levers 211, 212 are shown in a locked state. In order to unlock the plug housing 110 from the socket housing 210, the levers can be pivoted toward the socket connector 200. A seal 203 is provided between the plug housing 110 and the socket housing 210.

[0025] Figure 3 An example of a plug insert 130 is shown, which is suitable for use with Figure 1 or Figure 2 The plug housing 110 is shown for use in conjunction with. Figure 4 yes Figure 3 The plug insert 130 is shown in cross-sectional view taken along line IV-IV. Figure 5 yes Figure 3 A VV cross-sectional view of the plug insert 130 is shown. Two or more plug inserts 130 may be disposed adjacent to each other and fixed in the plug housing 110 .

[0026] A single pin contact 150 is fixedly held within the plug insert 130. The pin contact 150 is capable of conducting a current of up to 100A. The pin contact 150 includes an annular groove 153 between a crimping portion 155 and a mating portion 156 of the pin contact 150. The annular groove 153 is axially disposed approximately midway between the front and rear ends of the pin contact 150. A forwardly bent contact retaining arm 135 extends on the inner side from the narrow side wall 132. "Forward" here refers to an orientation from the wire connection side toward the insertion side of the connector. The forwardly bent contact retaining arm 135 includes inwardly directed chamfered protrusions 136 that engage with the annular groove 153. The pin contact 150 is thereby fixed to the plug insert 130 by the forwardly bent contact retaining arm 135.

[0027] Typically, objects smaller than 12 mm in size, such as a human finger, can access the pin contacts 150. The access opening 131 in front of the forwardly bent contact holding arm 135 must be wide enough to allow access to the contact holding arm 135 to release and remove the pin contacts 150 for maintenance.

[0028] like Figure 4As shown, the metal part of the pin contact 150 meets the IP20 protection level and cannot be reached by small objects with a minimum extension of less than 12 mm. Ingress protection is achieved by the contact tip insulator 160 and the ingress protection frame 170.

[0029] The contact tip insulator 160 has a hollow cylinder into which the tip of the pin contact 150 is inserted. Therefore, the contact tip insulator 160 forms a forward extension of the pin contact 150 at its insertion side. The contact tip insulator 160 includes an annular chamfered protrusion 161 at its rear end. The annular chamfered protrusion 161 engages with an undercut annular groove 152 formed in the hollow tip 152 of the pin contact 150. The contact tip insulator 160 is made of an elastically deformable electrically insulating material, for example, rubber.

[0030] The entry opening 131 spans between the tip of the pin contact 150 and the narrow side wall 132 of the plug insert 130. The entry opening 131 in the example shown is larger than 12 mm, allowing fingers to reach the pin contact 150 and not meeting the IP20 protection rating. Therefore, the entry protection frame 170 is arranged between the narrow side wall 132 of the plug insert 130 and the pin contact 150. The remaining entry opening 171 between the entry protection frame 170 and the pin contact 150 is narrower than 12 mm, at which point the connector is finger-safe and IP20 rated.

[0031] Figure 6 is a perspective rear view of inlet protection frame 170 . Figure 7 1 is a perspective front view thereof. The inlet protection frame 170 has a generally rectangular base plate 173 disposed at a rear end thereof. A central contact opening 172 extends through the base plate 173. When the inlet protection frame 170 is inserted into the plug insert 130, the pin contacts 150 extend through the central contact opening 172.

[0032] Four retention arms 174 extend forward from the base plate 173. Each of the four retention arms 174 is arranged near each corner of the base plate 173. A chamfered protrusion 175 extends outward near the front end of each of the four retention arms 174. The chamfered protrusion 175 engages with the window 133 formed in the wide side wall 134 of the plug insert 130. The four retention arms 174 and their chamfered protrusions 175 thus form a snap fit with the window 133 of the plug insert 130. The snap fit between the inlet protection frame 170 and the plug insert 130 is releasable, and the inlet protection frame 170 is a removable inlet protection element.

[0033] Two generally cubic entrance barriers 176 extend forward from the base plate 173. The two generally cubic entrance barriers 176 extend parallel to and adjacent to the pin contacts 150. The front ends of the two generally cubic entrance barriers 176 are in the same plane as the front ends of the contact tip insulators 160 and the side walls 132, 134 of the plug insert 130. The two generally cubic entrance barriers 176 are disposed on opposite sides of the pin contacts 150 between the pin contacts 150 and the narrow side walls 132.

[0034] The inlet protection frame 170 is an optional component that can be used in conjunction with the plug insert 130 when IP20 finger safety is required. In this case, the inlet protection frame 170 can be clipped into the plug insert 130 from the insertion side. The plug insert 130 can also be used alternately without the inlet protection frame 170 when IP20 finger safety is not required. The inlet protection frame 170 does not contribute to the structural integrity of the plug insert 130. The usability of the plug connector 100 for making electrical connections is not affected by the presence or absence of the inlet protection frame 170.

[0035] The use of the inlet protection frame 170 allows retrofitting of existing plug connectors 100 that were not originally designed for finger safety.

[0036] Although the present invention has been described with reference to exemplary embodiments, it will be apparent to those skilled in the art that the present invention is not limited to the embodiments disclosed or shown, but on the contrary, the present invention is intended to cover many other modifications, substitutions, variations and a wide range of equivalent arrangements included within the spirit and scope of the appended claims.

Claims

1. An electrical plug connector (100), comprising: Plug insert (130); A pin contact (150) disposed within the plug insert (130); a contact tip insulator (160) fastened to the front end of the pin contact (150); a plurality of contact retaining arms (135) extending from a side wall (132) of the plug insert (130) toward the pin contacts (150) for securing the pin contacts (150) in the plug insert (130); as well as A removable inlet protection frame (170) includes an inlet barrier (176) disposed between the side wall (132) and the pin contact (150) in front of the contact retention arm (135).

2. The electrical plug connector (100) according to claim 1, in, When the entry protection frame (170) is removed from the connector for maintenance, the entry opening (131) between the side wall (132) and the contact tip insulator (160) is wider than 12 mm, and Wherein, when the inlet protection frame (170) is installed in the connector (100), the remaining inlet opening (171) between the side wall (132) and the contact tip insulator (160) is narrower than 12 mm.

3. The electrical plug connector (100) according to claim 1, in, The inlet protection frame (170) comprises: a substrate (173), and A plurality of retention arms (174) extending forward from the base plate (173), and The retaining arms (174) each include a chamfered protrusion (175) extending outward near the front end thereof, and the retaining arms (174) and their chamfered protrusions (175) form a snap connection with the window (133) of the plug insert (130).

4. The electrical plug connector (100) according to claim 3, wherein: The entry barrier (176) extends forwardly from the base plate (173).

5. The electrical plug connector (100) according to claim 3, wherein: The substrate (173) includes a central contact opening (172).

6. The electrical plug connector (100) according to claim 1, wherein: The entry barrier (176) is generally cubic in shape.

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