High-voltage electric connector, contact assembly, connection cable and vehicle

Abstract

The invention relates to a high-voltage electric connector, a contact assembly, a connection cable and a vehicle. A high-voltage electrical connector (100) is used for establishing a safe and frictionless electrical connection (E) to a connection receiving pin (202) extending in a longitudinal direction (L). The high-voltage electrical connector (100) comprises at least one contact element (102) for connecting a respective connection-receiving pin (202) and a drive element (104). The drive element is configured to move the contact element from an insertion state (IS), in which a position (Pc) of the contact element in the longitudinal direction at least partially overlaps a position (Pp) of the pin, to a contact state (CS), in which a mechanical contact (M) is established between the contact element and the pin. According to the invention, in the inserted state, the contact element and the pin are separated by a distance (D) in a radial direction perpendicular to the longitudinal direction.

Description

Technical Field

[0001] The present invention relates to a high-voltage electrical connector for establishing an electrical connection with one or more pins extending in a longitudinal direction, the high-voltage electrical connector including at least one contact element for contacting a respective pin.

[0002] The present invention also relates to a contact assembly for establishing an electrical connection to a connecting cable, to a method for establishing an electrical connection between a high-voltage electrical connector and a pin, to a vehicle (in particular an electric vehicle), and to a commercial vehicle. Background Art

[0003] High-voltage electrical connectors of the above type are in principle known in the art. High-voltage electrical connectors applied at commercial vehicles are generally subject to a hazardous environment and thus need to resist such an environment and should also be designed to withstand as many usage cycles as possible while safely protecting high-voltage transmission during use.

[0004] For example, in US 2020 / 0176935 A1, a high-voltage connector connected to a device is described, which experiences reduced electromagnetic interference (EMI), avoids galvanic corrosion of different metals inside or outside a fluid environment, and provides an effective electrical grounding system.

[0005] The scientific publication "Influence of corrosion process on friction and wear of tincoating of wire connector" (Tribology, Volume 6, 2020, pages 13 - 19, ISSN 0208 - 7774, DOI: 10.5604 / 01.3001.0014.8331) describes the results of metallographic, tribological, and microscopic tests of wire connectors.

[0006] This document shows that there are significant differences in the structure and thickness of a tin layer (or generally any coating) on a copper element (or generally on a substrate). It contains the results of tribological investigations of electrical connectors in an initial state and covered with an oxide layer generated by corrosion. The results of the tribological tests show that the oxide layer has a great influence on the friction and wear of the coating. The measurement results of the friction coefficient are confirmed by microscopic observations. Figures 7, 8, and 9 in this scientific publication show scanning electron microscope (SEM) images of the surface topography of wear marks caused by friction.

[0007] Therefore, one of the reasons for the low number of mating cycles of the high-voltage connector is the limited contact surface resistance. Due to the friction generated during mating, the contact surface degrades. After a certain number of mating cycles, the contact surface and its coating are damaged to such an extent that the contact resistance becomes too high to allow safe operation. Summary of the Invention

[0008] This is where the present invention comes in. The object of the present invention is to provide an electrical connector that can achieve more mating cycles, thereby extending its service life, and the high-voltage electrical connector should be suitable for establishing a safe electrical connection even considering more mating cycles.

[0009] The first aspect of the present invention achieves this object by means of a high-voltage electrical connector according to claim 1 or a method for establishing a safe electrical connection.

[0010] The high-voltage electrical connector is suitable for establishing a safe and in particular frictionless electrical connection with one or more connection receiving pins extending in the longitudinal direction. The receiving pins are also referred to as tab contacts.

[0011] The high-voltage electrical connector includes at least one contact element (also referred to as a receiving part contact) for connecting the corresponding pins and a drive element configured to move the at least one contact element from an insertion state to a contact state, wherein in the insertion state, the position of the contact element in the longitudinal direction at least partially overlaps the position of the corresponding pin, and in the contact state, mechanical contact is established between the contact element and the pin, and wherein, at the at least partially overlapping position in the insertion state, the contact element and the pin are separated by a certain distance in the radial direction perpendicular to the longitudinal direction.

[0012] In the insertion state, the contact element and the pin have an overlapping position, i.e., the projections of the contact element and the pin in the longitudinal direction overlap. However, since the contact element and the pin are separated by a certain distance in the radial direction perpendicular to the longitudinal direction, electrical contact is not yet provided. Once in this insertion state, the drive element is advantageously configured to drive the movement of the contact element such that the radial distance between the contact element and the pin is reduced until mechanical contact is established between the contact element and the corresponding pin. Therefore, there is no sliding of the contact element against the pin as in known connectors, and the stress on the contact surface is significantly reduced, thereby enabling a greater number of mating cycles. According to the present invention, the final mating position between the contact element and the corresponding pin or tab contact is reached from a substantially perpendicular direction without friction in the longitudinal direction. In other words, once the connector is in the connected state, the connection is established by a substantially radial movement of the receiving part contact or the contact element, thereby reducing or even eliminating friction.

[0013] Further advantageous developments of the invention are reflected in the dependent claims and elaborate on the advantageous possibilities of implementing the above concepts within the scope of the above objectives and with regard to other advantages.

[0014] In the following, a development of the high-voltage electrical connector of the first aspect will be discussed.

[0015] In the framework of the present invention, the term high voltage refers to a DC voltage value higher than 20 VDC, preferably higher than 30 VDC, and more preferably higher than 50 VDC. However, a high-voltage electrical connector can also be used for electrical connections involving lower voltage values. Preferably, and for safety reasons, the contact elements are accommodated within a housing element. The housing element, in particular a protective housing element, defines an internal volume in which the contact elements are arranged such that the risk of a user touching the contact elements is minimized. The housing element is preferably configured to mate with a corresponding housing element of the pin, in particular in the form of a respective protective housing element, such that in the inserted state, the user cannot access the contact elements and the pins from the outside of the housing element, and the risk of electric shock is reduced.

[0016] In one development, the drive element includes an actuator unit that is configured to drive the movement of the contact element in a radial direction such that in a first actuation state of the actuator unit, the contact element and the pin are separated by the amount of distance, and in a second actuation state of the actuator unit, a mechanical contact is established between the contact element and the pin. The actuator can be implemented as a button or a set of buttons or a bistable actuator in different developments.

[0017] In another development, the drive element is further configured to move the contact element in a longitudinal direction until the position of the contact element in the longitudinal direction at least partially overlaps with the position of the pin, and the contact element and the pin are separated by the amount of distance.

[0018] In the coupled state, the housing element of the electrical connector is connected to the housing element of the pin. For example, the drive element is configured to move the contact element from the coupled state to the inserted state and from the inserted state to the contact state. Thus, in one development, the user brings the high-voltage electrical connector and the pin into the coupled state, and then the drive element first moves the contact element to the inserted state and subsequently to the contact state, in which an electrical connection is established.

[0019] In yet another development, the drive element includes a guiding element that is coupled to the contact element and is configured to guide the movement of the contact element along a first section and to guide the movement of the contact element along a second section, where in the first section, the guiding element extends substantially parallel to the longitudinal direction, and where in the second section, the guiding element extends in the radial direction. In one development, the first section that extends substantially parallel to the longitudinal extension corresponds to the movement of the contact element from the coupled position to the inserted position, and the second section having a radial component corresponds to the movement of the contact element from the inserted state to the contacting state. Preferably, the end section of the second section corresponding to the distal end of the guiding element is arranged perpendicular to the longitudinal direction such that there is no friction or sliding in the actual mechanical contact between the contact element and the corresponding pin.

[0020] In another development, the drive element includes an actuator that is configured to drive the movement of the contact element in the radial direction when moving the contact element from the inserted state to the contacting state. Preferably, the actuator is configured to drive the movement of the contact element in the longitudinal direction before driving the movement of the contact element in the radial direction. The actuator can also be configured to mechanically fix the connection between the high-voltage electrical connector and its corresponding part (i.e., the cooperating connector including the pins) such that accidental disconnection is avoided. Thus, the actuator can be a rotating rod that rotates when actuated and causes the movement of the contact element relative to the pins, and then mechanically fixes the connection between the high-voltage electrical connector and its corresponding part through a fastening mechanism.

[0021] In yet another embodiment, the high-voltage electrical connector further includes a fastening unit that is configured to releasably fix the contact element in the contacting state, i.e., the fastening unit is configured to effect a fixed connection and release said fixed connection. This reduces the risk of accidental decoupling of the mechanical contact between the contact element and the pins by forcing mechanical contact by fixing the relative position between the contact element and the pins. In order to decouple the mechanical contact, the fastening unit must be actively actuated such that the contact element can move away from the pins.

[0022] Preferably, in another development, in order to disconnect the mechanical connection between the contact element and the pins, the drive element is also configured to move the at least one contact element from the contacting state, radially away from the pins, and to move to the inserted state, where in the contacting state, a mechanical contact is established between the contact element and the pins, and in the inserted state, the position of the contact element along the longitudinal direction overlaps with the position of the corresponding pin, and the contact element and the pin are separated by a certain distance amount. Thus, in this development, the movement between the inserted state and the connected state is reversible, and thus, this also reduces or avoids damage to the contact element and / or the pins during the disengagement of the high-voltage electrical connector.

[0023] The high-voltage electrical connector according to the first aspect of the present invention may include a plurality of contact elements for contacting one or more pins. For example, in one development, the high-voltage electrical connector includes two contact elements for contacting the pins such that contact is established at substantially opposite sides of the pins, such that when in contact, the force applied to the pin by one of the contact elements cancels out the force applied to the pin by the other contact element. In another development, the high-voltage electrical connector includes multiple sets of two contact elements, each set of two contact elements being configured to contact a corresponding pin. Exemplary high-voltage electrical connectors may include two, three, four, five, six, seven, eight, nine, ten or more sets of one or more contact elements for contacting corresponding pins.

[0024] The second aspect of the present invention is formed by a contact assembly adapted to establish an electrical connection. The contact assembly includes a socket element and a high-voltage electrical connector according to any one of the preceding claims, wherein the socket element includes at least one pin extending in a longitudinal direction. Preferably, in one development, the socket includes a housing element, in particular a protective housing element, which defines an internal volume in which the pins are arranged such that the pins do not protrude from the internal volume. For safety reasons, it is also preferred that the high-voltage electrical connector further includes a housing element defining an internal volume in which the contact elements are arranged. When the connector and the socket are mated to establish a mechanical connection between the contact elements and the pins, the housing element of the socket and the housing element of the high-voltage electrical connector cooperate.

[0025] Thus, the contact assembly according to the second aspect of the present invention has the advantages of the high-voltage electrical connector of the first aspect.

[0026] The third aspect of the present invention is formed by a connecting cable. The connecting cable of the present invention includes at least one high-voltage electrical connector according to the first aspect of the present invention. The high-voltage electrical connector is arranged at one end of the connecting cable, and the connecting cable further includes one or more electrical wires connected to the at least one high-voltage electrical connector. Preferably, in a particular development, the connecting cable includes a high-voltage electrical connector according to the first aspect of the present invention, the high-voltage electrical connector being attached to the corresponding end of the connecting cable.

[0027] The fourth aspect of the present invention is formed by a method for establishing an electrical connection between a high-voltage electrical connector according to the first aspect and a pin extending in a longitudinal direction. The method includes moving at least one contact element of the high-voltage electrical connector from an insertion state to a contact state, wherein in the insertion state, the position of the contact element in the longitudinal direction at least partially overlaps the position of the corresponding pin, and the contact element and the pin are separated by a certain distance amount in a radial direction perpendicular to the longitudinal direction, and in the contact state, mechanical contact is established between the contact element and the pin. In a preferred development, the method further includes a previous step that includes moving the contact element in the longitudinal direction until the position of the contact element in the longitudinal direction at least partially overlaps the position of the pin, and before moving the contact element in the radial direction, the contact element and the pin are separated by a certain distance amount.

[0028] In a fifth aspect, the present invention also relates to a vehicle, in particular an electric vehicle, which includes a contact assembly according to the second aspect of the present invention and / or a connection cable according to the third aspect of the present invention, in particular for an electrical connection between a battery unit and a junction box of the vehicle. The junction box (also known as a high-voltage junction box) simplifies the conversion of electric vehicles and the installation of electric vehicle equipment by integrating several aspects of the conversion of electric vehicles into a plug-and-play solution. It is connected to a high-voltage battery unit and generally includes motor and controller feeders, main fuses and auxiliary fuses, a battery management system, high-voltage contacts (such as pins to be connected to a high-voltage electrical connector), charging controls, and relays.

[0029] The vehicle according to the present invention may also be a commercial vehicle including a cab and a trailer, wherein at least one high-voltage electrical connector according to the first aspect of the present invention is used to establish an electrical connection between a first set of one or more pins located in the cab and a second set of corresponding pins located in the trailer. Since the number of mating cycles achieved by using the high-voltage electrical connector of the present invention is increased, it is particularly advantageous to electrically couple the cab and the trailer using the high-voltage electrical connector of the present invention. Preferably, a connection cable according to the third aspect of the present invention is used to establish the electrical connection.

[0030] These and other aspects of the present invention will be apparent from and will be elucidated with reference to the embodiments described hereinafter.

[0031] The embodiments of the present invention will be described below based on the accompanying drawings in comparison with the prior art, and the prior art is also partially shown. The latter is not necessarily intended to represent the embodiments to scale. In cases of explanation, the drawings are shown in schematic and / or slightly distorted forms. For supplementary content regarding the teachings directly recognizable in the figures, reference may be made to the relevant prior art. It should be noted that many modifications and changes can be made to the form and details of the embodiments without departing from the general concept of the present invention. The features of the present invention disclosed in the specification, the drawings, and the claims, either individually or in any combination, may be crucial for the further development of the present invention. In addition, all combinations of at least two features disclosed in the specification, the drawings, and / or the claims fall within the scope of the present invention.

[0032] The general concept of the present invention is not limited to the exact form or details or subject matter of the preferred embodiments shown and described below, and it will be limited compared to the subject matter claimed in the claims.

[0033] For a specified design range, the values within the specified limits of the range are also disclosed as limit values and are thus arbitrarily applicable and claimable. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] The following drawings show:

[0035] Figure 1A is a schematic block diagram of a first exemplary embodiment of a contact assembly including a high-voltage electrical connector in an inserted state according to the present invention;

[0036] Figure 1B is Figure 1A a schematic block diagram of an exemplary contact assembly, wherein the high-voltage electrical connector is in a contact state;

[0037] Figure 2A is a schematic block diagram of a second exemplary embodiment of a contact assembly including a high-voltage electrical connector before mating with a corresponding socket according to the present invention;

[0038] Figure 2B is Figure 2A a schematic block diagram of an exemplary contact assembly, wherein the high-voltage electrical connector is in an inserted state;

[0039] Figure 2C is Figure 2A a schematic block diagram of an exemplary contact assembly, wherein the high-voltage electrical connector is in a contact state;

[0040] Figure 3A is a schematic block diagram of a second exemplary embodiment of a contact assembly including a high-voltage electrical connector in a so-called coupled state according to the present invention;

[0041] Figure 3B isFigure 3A Schematic block diagram of an exemplary contact assembly, where the high-voltage electrical connector is in the inserted state;

[0042] Figure 3C is Figure 3A Schematic block diagram of an exemplary contact assembly, where the high-voltage electrical connector is in the contacting state;

[0043] Figure 4 Schematic diagram of an exemplary connection cable according to the present invention;

[0044] Figure 5 Schematic block diagram of an exemplary commercial vehicle including a connection cable according to the present invention; and

[0045] Figure 6 Flowchart of an exemplary inventive method for establishing an electrical connection between a high-voltage electrical connector according to any one of the preceding claims 1-7 and a pin extending in the longitudinal direction; Detailed Description

[0046] Figure 1A Shows a schematic block diagram of a first exemplary embodiment of a contact assembly 200 including a high-voltage (HV) electrical connector 100 in the inserted state IS according to the present invention. Further, Figure 1B Shows Figure 1A Schematic block diagram of an exemplary contact assembly 200, where the high-voltage electrical connector 100 is in the contacting state CS.

[0047] The contact assembly 200 is adapted to establish an electrical connection between two terminals. The contact assembly 200 includes a socket element 201, which includes at least one pin 202 extending in the longitudinal direction L. The contact assembly 200 further includes a high-voltage electrical connector 100 for establishing an electrical connection E with the pin 202. The high-voltage electrical connector 100 includes a set of two contact elements 102, which also extend in the longitudinal direction and are arranged and configured to connect to the pin 202. The HV electrical connector 100 includes a drive element 104, which is configured to move the contact elements 102 from Figure 1A the inserted state IS shown to the contacting state CS (see Figure 1B), wherein in this insertion state IS, the projection of the position Pc of the contact element 102 along the longitudinal direction L at least partially overlaps with the projection of the position Pp of the pin 202 in the longitudinal direction, and in this insertion state IS, the contact element 102 and the pin 202 are separated by a distance D, which distance D is measured in the radial direction perpendicular to the longitudinal direction. In this contact state CS, a mechanical contact M is established between the contact element 102 and the pin 202. Here, the contact element is arranged to contact the pin at the opposite side of the pin, such that the force exerted on the pin 202 by one of the contact elements is cancelled out by the force exerted by the other pin. Thus, the resultant force on the pin is substantially zero. In other exemplary HV electrical connectors (not shown), there are three contact elements for each contact pin, and contacts are established at three corresponding positions, where the relative angle between two contact elements is 120°.

[0048] Figure 2A Fig. shows a schematic block diagram of a second exemplary embodiment of a contact assembly 200 including a high-voltage electrical connector 100 before mating with a corresponding socket element 201. For simplicity, the same reference numerals are used for those technical features having the same or similar functions. To increase safety during operation and comply with safety regulations, the contact element 102 is housed within a housing element 101 (in particular, a housing element or enclosure) of the HV electrical connector 100. The housing element 101 defines an internal volume 103, and the contact element 102 is arranged within the internal volume 103. Preferably, the contact element 102 does not protrude from the internal volume 103 when not mated (i.e., in a non-coupled state). Similarly, the socket element 210 also includes a corresponding housing element 205, which defines an internal volume 203, and the pin 202 is arranged within the internal volume 203. Also preferably, the pin 202 does not protrude from the internal volume 203. Figures 2A to 2C The shown contact element 102 has an S-shaped configuration. Starting from the proximal end, the distance between the two contact elements first decreases until a minimum spacing distance is reached, and then increases again towards the distal end. The region where the separation distance of the contact element 102 is minimum is the region where contact with the pin will be established, and it is preferably found at the same position along the longitudinal direction for all contact elements 102.

[0049] Figure 2B Fig. shows Figure 2A a schematic block diagram of an exemplary contact assembly 200, where the high-voltage electrical connector is in the insertion state IS. Now, the HV electrical connector 100 is coupled to the socket element 210, and the projection of the position of the contact element 102 along the longitudinal direction L at least partially overlaps with the projection of the position of the pin in the longitudinal direction. In Figure 2BIn the inserted state shown, the contact element 102 and the pin 202 are separated by a certain distance in the radial direction perpendicular to the longitudinal direction.

[0050] Figure 2C An exemplary contact assembly is shown in a schematic block diagram, where the high-voltage electrical connector is in a contact state. To achieve this contact state, the drive element 104 ( Figure 2A shown in Figure 1A , Figure 1B ) is actuated. Actuation of the drive element causes the contact element 102 to move from the Figure 2B shown position (i.e., the inserted state) to a position where mechanical contact is established between the contact element 102 and the pin 202. By actuating the drive element 104 (in the form of an actuator unit 106 in this example), the contact element 102 moves in the radial direction until mechanical contact is established, thereby avoiding sliding friction between the cooperating contact element 102 and the pin 202. The actuator unit 106 is configured to drive the movement of the contact element 102 in the radial direction such that in a first actuation state A1 of the actuator unit 106 (see, for example, Figure 2A and Figure 2B ), the contact element 102 and the pin 202 are separated by a distance D, while in a second actuation state A2 of the actuator unit 106 (see, for example, Figure 2C ), mechanical contact M is established between the contact element 102 and the pin 202.

[0051] Figures 2A to 2C The HV electrical contact 100 of

[0052] also includes a fastening unit 109, which is configured to releasably fix the contact element 102 in the contact state CS. For example, the fastening unit 109 is configured to slide along the housing element 101 and prevent the actuator unit from moving back from the second actuation state A2 to the first actuation state A1, thus fixing the mechanical contact between the contact element 102 and the pin 202.

[0053] Figures 3A to 3C A contact assembly 200 including a high-voltage electrical connector 100 according to the present invention in three different states during the mating process is shown in a schematic block diagram of a second exemplary embodiment.

[0054] In Figure 3Ashows the midpoint towards the insertion state, starting from the coupling state where the housing element 101 of the HV electrical connector 100 is coupled to the housing element 205 of the socket element 201.

[0055] Figure 3B Shows the contact assembly 200, where the contact element 102 of the HV electrical connector 100 is in the inserted state.

[0056] Figure 3C Shows the contact assembly 200, where the contact element of the HV electrical connector 100 is in the contact state, i.e., a mechanical contact M with the pin 102 has been established.

[0057] In Figures 3A to 3C In the exemplary high-voltage electrical connector 100, the drive element 104 is also configured to move the contact element 102 in the longitudinal direction. The contact element 102 is moved until the projection of the position of the contact element 102 along the longitudinal direction L at least partially overlaps the projection of the position of the pin 202 along the longitudinal direction; in this state, the contact element 102 and the pin 202 are separated by a certain distance amount. In particular, the drive element 104 includes a guiding element 108, which is coupled to the contact element 102 and is configured to guide the movement of the contact element along a first section S1 and along a second section S2, where at this first section S1, the guiding element 108 extends parallel to the longitudinal direction L, and at the second section S2, the guiding element extends substantially along the radial direction R. These first and second sections are shown in Figure 3B The guiding element 108 may for example include a track 108 having a straight first section S1 and a curved second section, and the contact element is coupled to the track. The position of the guide rail is fixed relative to the housing element 101, and the contact element 102 is movable on the guide rail, and thus their position is variable relative to the housing element 101. At the end of the straight first section S1, the contact element 102 is in the inserted position. Further actuation of the drive element 104 causes the contact element 102 to move towards the pin until the mechanical contact M is established. Preferably, the end section of the guiding element 108 has a direction parallel to the radial direction R in order to minimize the risk of the contact element 102 sliding against the pin 202. The contact position P between the track 108 and the contact element 102 is indicated by a dot.

[0058] Figure 4 is a schematic diagram of an exemplary connection cable 300 according to an embodiment of the present invention. The connector cable 300 includes a high-voltage electrical connector 100 arranged at the first end 302 of the connection cable, and one or more electrical wires 306, which are connected to the at least one high-voltage electrical connector 100.

[0059] In the cable 300 of the embodiment, the second end 304 of the cable is attached to another electrical connector 150, which may also be a high-voltage electrical connector according to the present invention. The cable 300 may be implemented as an extension cable, i.e., a cable that enables the use of an electrical appliance at a distance from a fixed socket.

[0060] Figure 5 An exemplary vehicle 500 is shown in a schematic block diagram, in particular an electric vehicle including a connection cable 300 according to the present invention, in particular for an electrical connection between a battery unit 502 and a junction box 504 of the vehicle 500. Exemplarily, the vehicle 500 is a commercial vehicle 600, which includes a cab 602 and a trailer 604, and in which at least one high-voltage electrical connector 100 according to the present invention is used, and in particular a connection cable 300 also according to the present invention is used to establish an electrical connection between a first set of one or more pins located in the cab 602 and a second set of corresponding pins located in the trailer 604. Via the connection cable 300 between the trailer and the cab, the battery unit 502 in the cab is electrically connected to an electrical load in the trailer, and power supply to the trailer is enabled. The increased number of mating cycles achieved by the high-voltage electrical connector 100 due to the reduced friction between the contact elements and the pins is particularly advantageous for electrical connections, especially high-voltage electrical connections, which must be regularly connected and disconnected, such as the electrical connection between the cab 602 and the trailer 604.

[0061] Figure 6 is a flowchart of an exemplary method 700 for establishing an electrical connection between a high-voltage electrical connector 100 and a pin extending in a longitudinal direction as described above. The method includes: in step 702, before moving the contact element in a radial direction, moving the contact element in a longitudinal direction until the position of the contact element in the longitudinal direction overlaps with the position of the pin, and the contact element and the pin are separated by a certain distance amount, which is referred to as the insertion state. The method 700 further includes, in step 704, moving the element of the high-voltage electrical connector from the insertion state to the contact state, wherein in the insertion state, the position of the contact element in the longitudinal direction overlaps with the position of the corresponding pin, and the contact element and the pin are separated by a certain distance amount in a radial direction perpendicular to the longitudinal direction, and in the contact state, mechanical contact is established between the contact element and the pin.

[0062] In summary, the present invention relates to a high-voltage electrical connector for establishing a secure and frictionless electrical connection to a connection receiving pin, also known as a tab contact, which extends in a longitudinal direction, the high-voltage electrical connector comprising at least one contact element for connecting a respective connection receiving pin and a drive element. The drive element is configured to move the contact element from an insertion state, in which the position of the contact element in the longitudinal direction at least partially overlaps the position of the pin, to a contact state, in which mechanical contact is established between the contact element and the pin. According to the invention, in the insertion state, the contact element and the pin are separated by a certain distance in a radial direction perpendicular to the longitudinal direction.

[0063] From the study of the drawings, the disclosure, and the appended claims, those skilled in the art can understand and implement other variations of the disclosed embodiments.

[0064] In the claims, the word "comprising" does not exclude other elements or steps, and the indefinite article "a" or "an" does not exclude a plurality.

[0065] A single unit or device may perform the functions of several items recited in the claims. The fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used advantageously. Any reference signs in the claims should not be construed as limiting the scope.

[0066] List of reference signs (part of the description)

[0067] 100 High-voltage - HV - electrical connector

[0068] 101 Housing element of the HV electrical connector

[0069] 102 Contact element / receptacle contact

[0070] 103 Internal volume of the HV electrical connector

[0071] 104 Drive element

[0072] 106 Actuator unit

[0073] 108 Guide element

[0074] 109 Fastening unit

[0075] 150 Electrical connector

[0076] 200 Contact assembly

[0077] 201 Socket element

[0078] 202 Connection receiving pin / tab contact

[0079] Internal volume of the 203 socket element

[0080] Outer shell element of the 205 socket element

[0081] 210 socket element

[0082] 300 Connecting cable

[0083] First end of the 302 connecting cable

[0084] Second end of the 304 connecting cable

[0085] 306 Electric wire

[0086] 500 Vehicle, electric vehicle

[0087] 502 Battery unit

[0088] 504 Junction box

[0089] 600 Commercial vehicle

[0090] 602 Compartment

[0091] 603 First set of one or more pins

[0092] 604 Trailer

[0093] 605 Second set of one or more pins

[0094] 700 Method

[0095] 702 Method step

[0096] 704 Step

[0097] A1 First actuation state

[0098] A2 Second actuation state

[0099] CS Contact state

[0100] D Distance measure

[0101] E Electrical connection

[0102] IS Insertion state

[0103] L Longitudinal direction

[0104] M Mechanical contact

[0105] R Radial direction

[0106] S1 Straight first section

[0107] S2 Bent second section

[0108] P Contact position

[0109] Position of the contact element when the Pc is in the inserted state

[0110] Position of the pin when the Pp is in the inserted state.

Claims

1. A high-voltage electrical connector (100) for establishing a secure electrical connection (E) to a connection receiving pin (202) extending in a longitudinal direction (L), the high-voltage electrical connector (100) comprising: - at least one contact element (102) for connecting a respective connection receiving pin (202) and a drive element (104), the drive element (104) being configured to move the contact element (102) from an insertion state (IS) to a contact state (CS): - in the insertion state (IS), a position (Pc) of the contact element (102) at least partially overlaps a position (Pp) of the connection receiving pin (202) along the longitudinal direction (L); - in the contact state (CS), a mechanical contact (M) is established between the contact element (102) and the connection receiving pin (202), characterized in that at least in the at least partially overlapping positions (Pc, Pp) of the insertion state (IS), the contact element (102) and the connection receiving pin (202) are separated by a distance amount (D) in a radial direction perpendicular to the longitudinal direction.

2. The high-voltage electrical connector (100) according to claim 1, wherein, The at least one contact element (102) is received within a housing element (101) that defines an internal volume (103), and the at least one contact element (102) is disposed within the internal volume.

3. The high-voltage electrical connector (100) according to claim 1 or 2, wherein, The drive element (104) includes an actuator unit (106) configured to drive the at least one contact element (102) to move in the radial direction (R) such that in a first actuation state (A1) of the actuator unit (106), the contact element (102) and the pin (202) are separated by the distance amount (D), and in a second actuation state (A2) of the actuator unit (106), the mechanical contact (M) between the contact element (102) and the pin (202) is established.

4. The high-voltage electrical connector (100) according to any one of the preceding claims, wherein, The drive element (104) is further configured to move the contact element (102) in the longitudinal direction (L) until the position (Pc) of the contact element (102) at least partially overlaps the position (Pp) of the pin (202) along the longitudinal direction (L), and the contact element (102) and the pin (202) are separated by the distance amount (D).

5. The high-voltage electrical connector (100) according to any one of the preceding claims, wherein, The drive element (104) includes a guiding element (108) coupled to the contact element (102) and configured to guide the contact element (102) to move along a first section (S1) and along a second section, wherein at the first section (S1), the guiding element (108) extends parallel to the longitudinal direction (L), and at the second section, the guiding element (108) extends in the radial direction (R).

6. The high-voltage electrical connector (100) according to any one of the preceding claims further comprises a fastening unit (109), the fastening unit (109) being configured to releasably fix the contact element (102) in the contact state (CS).

7. The high-voltage electrical connector (100) according to any one of the preceding claims, wherein, In order to disconnect the mechanical connection (M) between the contact element (102) and the connection receiving pin (202), the drive element (104) is further configured to move the at least one contact element (102) from the contact state (CS) radially away from the connection receiving pin (202) to the insertion state (IS), wherein in the contact state (CS), the mechanical contact (M) established between the contact element (102) and the connection receiving pin (202), in the insertion state (IS), the position of the contact element (102) along the longitudinal direction (L) overlaps with the position of the corresponding connection receiving pin (202), and the contact element (102) and the connection receiving pin (202) are separated by a distance amount (D).

8. A contact assembly (200) for establishing an electrical connection (E), the contact assembly (200) comprising a socket element (201) and a high-voltage electrical connector (100) according to any one of the preceding claims, wherein the socket element (201) comprises at least one connection receiving pin (202) extending along a longitudinal direction (L).

9. A connecting cable (300), the connecting cable comprising at least one high-voltage electrical connector (100) according to any one of the preceding claims 1-7 and one or more electrical wires (306), the high-voltage electrical connector (100) being arranged at respective ends (302, 304) of the connecting cable (300), the one or more electrical wires (306) being connected to the at least one high-voltage electrical connector (100).

10. A method (700) for establishing an electrical connection (E) between a high-voltage electrical connector (100) according to any one of the preceding claims 1 to 7 and a connection receiving pin (202) extending in a longitudinal direction (L), the method comprising: - moving (704) the at least one contact element (102) of the high-voltage electrical connector (100) from the insertion state (IS) in a radial direction (R) perpendicular to the longitudinal direction (L) to the contact state (CS), wherein in the insertion state (IS), the position of the contact element (102) along the longitudinal direction (L) overlaps with the position of the corresponding connection receiving pin (202), and the contact element (102) and the connection receiving pin (202) are separated by a distance amount (D), and in the contact state (CS), a mechanical contact (M) is established between the contact element (102) and the connection receiving pin (202).

11. The method (700) according to claim 10, further comprising: - Before moving the contact element (102) along the radial direction (R), move (702) the contact element (102) along the longitudinal direction (L) until the position of the contact element (102) along the longitudinal direction (L) overlaps with the position of the connection receiving pin (202) and the contact element (102) and the connection receiving pin (202) are separated by a distance amount (D).

12. A vehicle (500), in particular an electric vehicle (500), comprising the contact assembly (200) according to claim 8 and / or the connection cable (300) according to claim 9, in particular for an electrical connection between a battery cell (502) and a junction box (504) of the vehicle (500).

13. A commercial vehicle (600) includes a carriage (602) and a trailer (604), wherein, Establish an electrical connection (E) between a first set of one or more pins (603) located in the passenger compartment (602) and a second set of corresponding pins (605) located in the trailer (604) using at least one high-voltage electrical connector (100) according to any one of the preceding claims 1 to 7.

14. The commercial vehicle (600) according to claim 13, wherein, Establish the electrical connection (E) using the connection cable (300) according to claim 9.

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