High current plug connector system and method for setting total separing force thereof

Abstract

The aim of the invention is to enable, in a simple manner, a matching of the total separating force of the high-current plug connector system to a predetermined value and a corresponding retrofit of an existing high-current plug connector system to be designed as inexpensive as possible. To this end, the plug connector (1) and the mating plug connector (2) of the plug connector system are each provided with at least one further plug contact (100) or at least one further mating plug contact (200). The at least one further plug contact (100) and the at least one further mating plug contact (200) can be plugged to each other and can be separated from each other again in the plugged state when a single separating force is applied in order to jointly configure a predetermined quantity of the total separating force for generating the plug connector system. In this way, the desired total separating force can be individually set, for example by an end user, only with little effort by selecting a suitable further plug contact and mating plug contact and, for example, the actual current intensity can be adapted, the connections that transmit particularly high currents are particularly difficult to separate, in particular for safety reasons.

Description

Field of the Invention

[0001] The present invention is based on a high-current plug connector system of the type according to independent claim 1.

[0002] Furthermore, the present invention is based on a method for setting the total separation force of a high-current plug connector system according to claim 14.

[0003] Furthermore, the present invention is based on a method for setting the total separation force of a high-current plug connector system according to claim 15. Background Art

[0004] The term "total separation force" is to be understood herein and hereinafter as the force required to separate a plug connector, which is one of the two components of a high-current plug connector system, from a mating plug connector with which it is plugged.

[0005] Such a high-current plug connector system can be used, for example, to transmit electrical energy. In particular, via the high-current plug connector system, a total current with a high total current intensity of at least up to 16 A ("amperes"), for example at least up to 20 A, preferably at least up to 35 A, particularly preferably at least up to 70 A, especially at least up to 125 A, for example at least up to 300 A, and particularly even at least 900 A can be transmitted, not only via the plug connector but also via the mating plug connector.

[0006] In the prior art, plug connector systems consisting of a plug connector and a mating plug connector are known. The plug connector can be plugged into the mating plug connector and can be separated from the mating plug connector again under the total separation force. In the prior art, the total separation force is usually randomly generated by frictional forces, such as the sum of the insertion force and the extraction force caused by friction, especially of the effective electrical contact portion, the friction of the seal of the plug connector housing, and the like.

[0007] In practical use, the following requirement has emerged, namely that a specific plug connector system should have a defined total separation force according to its function. In particular, a high-current plug connector system designed to transmit a particularly high current intensity should have an equally particularly high total separation force for safety reasons.

[0008] It is disadvantageous in the prior art that the intensity of the total separation force cannot be easily set in existing high-current plug connector systems.

[0009] The German Patent and Trademark Office retrieved the following prior art in the priority application of this application: DE10 2019 111847A1, DE 10 2019 121 975A1, DE 11 2018 006 768T5, DE 14 65 689A, and US2021 / 0194167A1. Summary of the Invention

[0010] The object of the present invention is to describe a high-current plug connector system and a method by which it is possible, in particular in an individualized manner and in the simplest possible way, to set the total separation force of the high-current plug connector system to a preset value. Preferably, it should be possible to carry out a conversion of an existing high-current plug connector system with as little effort as possible. Particularly preferably, for this purpose, as few new components as possible are added or changes are made to the existing high-current plug connector system. In particular, the so-called "modularity" of the high-current plug connector system should be maintained to the greatest extent possible, that is to say, its components should already be present on the market to the greatest possible extent and can be used together with as many other market-common components as possible, i.e., at least plugged together and preferably also co-mounted as a plug connector system, in particular as a high-current plug connector system.

[0011] The object is achieved by the subject matter of the independent claims.

[0012] The high-current plug connector system has a plug connector and a mating plug connector. The plug connector and the mating plug connector can not only be plugged together but also separated from each other under the total separation force. The plug connector has a plurality of high-current plug contacts of the same type as each other. The mating plug connector has a plurality of high-current mating plug contacts that can be plugged with the high-current plug contacts. In the plugged state, each high-current plug contact in the high-current plug contacts is mechanically and conductively connected to one of the high-current mating plug contacts in the high-current mating plug contacts to form one high-current plug contact pair each for transmitting electrical energy.

[0013] In addition, the plug connector has at least one further plug contact and the mating plug connector has at least one further mating plug contact. Each of the further plug contacts in the further plug contacts and one of the further mating plug contacts in the further mating plug contacts respectively form a further plug contact pair. The further plug contact and the further mating plug contact of each plug contact pair can be plugged together under the application of a single insertion force and can be separated from each other again under the application of a single separation force in the plugged state. Thereby, the further plug contact and the further mating plug contact are jointly configured to generate a preset amount of the total separation force, wherein the single separation force of each further plug contact pair is at least 1.5 times its single insertion force.

[0014] It is known to those skilled in the art here and hereinafter that the term "single separation force" respectively relates to exactly one plug contact pair.

[0015] Preferably, a single separating force can be at least 1.75 times a single plugging force.

[0016] In particular, a single separating force can be at least twice a single plugging force.

[0017] For example, a single separating force can be at least 2.5 times a single plugging force

[0018] In a particularly preferred design, a single separating force can be even at least three times, in particular even at least four times and particularly preferably even at least five times a single plugging force.

[0019] Advantageous designs of the invention are specified in the dependent claims and in the following description.

[0020] One advantage of the invention is that the conversion of existing high-current plug connector systems can be designed particularly inexpensively. Finally, only one or, if necessary, a plurality of high-current plug contact pairs have to be replaced by one or more other plug contact pairs with respect to the already existing high-current plug connector system.

[0021] Particularly advantageously, the so-called "modularity" of the high-current plug connector system is maintained to the greatest possible extent, i.e. all its components can already be present on the market beforehand and can also be used together with other commonly available components on the market, i.e. they can not only be plugged with commonly available plug connectors on the market, but preferably can also be installed together with other commonly available components on the market into other plug connector systems / high-current plug connector systems. The above solution is thus distinguished in this respect from other conceivable, also less favorable solutions in which, for example, one or more plug connector housings, locking systems or other components have to be modified in order to regulate the total separating force.

[0022] One advantage of the invention is that the total separating force of a high-current plug connector system can be individually set to a preset value in a very inexpensive manner. Finally, it is only necessary to replace at least one high-current plug contact in the high-current plug contacts of a commonly available high-current plug connector system by another plug contact and to replace one high-current mating plug contact in the high-current mating plug contacts of a commonly available high-current plug connector system by another mating plug contact. Finally, replacing the plug contacts is a common operation, which is also usually carried out by the end customer and thus only incurs extremely little cost.

[0023] In an advantageous design, additional plug contacts and additional mating plug contacts can be correspondingly implemented at the factory in order to generate a specific single separating force, such that the total separating force at least corresponds to the load capacity of the high-current plug connection system. This has the advantage that it has been adjusted at the factory and the high-current plug connector system can be delivered to the end user pre-set with this adjustment.

[0024] In another advantageous design, the high-current plug connector system can additionally have an entire group of different additional plug contacts and different additional mating plug contacts, which generate different total separating forces when connected to each other. Thus, one or more suitable additional plug contacts and mating plug contacts can be selected from the group and used in the plug connector and the mating plug connector in order to set, in particular in combination with each other, the desired / pre-set total separating force. This has the advantage that the end user can individualize the total separating force according to their respective application, for example the range of the actually transmitted current intensity.

[0025] Therefore, the method for setting the total separating force of a high-current plug connector system proposes that the pre-set total separating force is set by selecting one or more suitable plug contacts and one or more suitable mating plug contacts from the group of different additional plug contacts and different additional mating plug contacts.

[0026] In a preferred design, the additional plug contacts and the additional mating plug contacts can be latched with each other in the plugged state in order to generate the total separating force or at least a part thereof by the individual separating forces formed upon their unlocking. Alternatively or additionally, friction can also act for this purpose.

[0027] In another preferred design, each high-current plug contact pair can be designed in the plugged state for transmitting a current intensity of at least 10 A ("amperes"), preferably at least 20 A, particularly preferably at least 40 A, especially at least 60 A, for example at least 70 A and especially even at least 80 A.

[0028] The term "designed" here means that the corresponding high-current plug contact pair can be continuously loaded with a current intensity "up to" the respectively given maximum value, i.e., loaded with a current intensity corresponding to the respectively given maximum value or less than the respectively given maximum value.

[0029] It is clear to the person skilled in the art that a high current load capacity, especially at a pre-set voltage, is advantageous for transmitting the highest possible electrical energy.

[0030] In another preferred design, the single separating force is at least 15 N ("Newton"), preferably at least 20 N, particularly preferably at least 25 N, especially at least 60 N, for example at least 75 N, for example at least 85 N and preferably even 97 N and more, for example at least 100 N, and if necessary even more than 110 N and more, i.e. for example 120 N and even more.

[0031] Thereby, the preset separating force can be, for example: 18 N; 22 N; 27 N; 67 N; 89 N; 111 N, 127 N.

[0032] The plug connector manufacturer is concerned with its statements and correlations regarding the maximum current load capacity, and can adjust the total separating force of the actually transmitted current intensity of the overall high-current plug connector system during the final user's fixed installation. The total current intensity is obtained from the sum of the current intensities of the individual currents flowing through the respective high-current plug contact pairs.

[0033] For example, for an actual total current intensity of 15 A, the preset total separating force can be 18 N.

[0034] For example, for an actual total current intensity of 16 A to 20 A, the preset total separating force can be 22 N.

[0035] For example, for an actual total current intensity of 21 A to 35 A, the preset total separating force can be 27 N.

[0036] For example, for an actual total current intensity of 36 A to 70 A, the preset total separating force can be 67 N.

[0037] For example, for an actual total current intensity of 71 A to 125 A, the preset total separating force can be 89 N.

[0038] In a preferred embodiment, the plug connector has at least one contact carrier, and the at least one contact carrier is formed of an electrically insulating material. The contact carrier can be integrally implemented as part of an integral plug connector assembly ("monoblock"). However, the plug connector can also have a plurality of plug connector modules, and the plurality of plug connector modules are inserted into a plug connector modular frame so as to form a modular plug connector assembly in this way. In the latter case, each plug connector module has a contact carrier, such that the plug connector then has a plurality of contact carriers.

[0039] The plug connector has a contact cavity for each high-current plug contact in the high-current plug contacts and also for each other plug contact in the other plug contacts. The contact cavity is provided in the contact carrier or distributed over a plurality of contact carriers and provided in a plurality of contact carriers.

[0040] Furthermore, the mating plug connector has at least one mating contact part carrier made of electrically insulating material. The mating contact part carrier can be integrally implemented as a component of the mating plug connector assembly ("monolithic"). However, the mating plug connector can also have a plurality of additional mating plug connector modules, which are inserted into the mating plug connector modular frame to form a modular mating plug connector assembly. In the latter case, each module has a mating contact part carrier, so that the mating plug connector then has a plurality of mating contact part carriers.

[0041] The mating high-current plug connector has mating contact cavities for each high-current mating plug contact part in the high-current mating plug contact parts and also for each additional mating plug contact part in the additional mating plug contact parts. The mating contact cavities are provided in the mating contact part carrier or distributed over a plurality of mating contact part carriers and provided in the mating contact part carrier.

[0042] In a preferred design, the contact cavities of the plug connector are implemented in the same shape. In another advantageous design, the mating contact cavities of the mating plug connector are implemented in the same shape.

[0043] This is advantageous in terms of the compatibility of the modularity with other possible product components, because in this way the corresponding contact part carrier / mating contact part carrier can be selectively equipped with not only high-current contact parts / high-current mating contact parts but also additional plug contact parts / mating plug contact parts in all contact receptacles.

[0044] In a preferred design, at least one contact part carrier has a cable connection side and a plug side opposite the cable connection side. The contact cavity is implemented as a through-opening that connects the cable connection side to the plug side.

[0045] Furthermore, at least one mating contact part carrier can have a mating cable connection side and a mating plug side opposite the mating cable connection side. The mating contact cavity can likewise be implemented as a through-opening that connects the mating cable connection side to the mating plug side.

[0046] At this point, it should be mentioned in the context that the terms "plug-in side", "cable connection side", "on the plug-in side", "on the cable connection side", and "plug-in direction" always refer to the associated plug connector or mating plug connector. The plug-in direction in the sense of a vector direction truly represents the same plug axis for the plug connector and the mating plug connector. The orientation always refers to the direction of plugging, that is, pointing to the respectively mating plug connector / mating plug connector. In the plugged-in state, the contact part carrier and the mating contact part carrier are oriented towards each other with their plug-in sides and mating plug-in sides and away from each other with their respective cable connection sides.

[0047] In another preferred embodiment, the high-current plug contact and one or more of the other plug contacts are respectively arranged in and held in one of the contact cavities of the plug connector. The high-current mating plug contact and one or more of the other mating plug contacts are respectively arranged in and held in one of the mating contact cavities of the mating plug connector.

[0048] This has the advantage that the other plug contacts, although different from the high-current plug contact, can be accommodated in contact receptacles of the same shape, which is beneficial for the modularization. Conventional contact part carriers can be used, for example. Only one additional plug contact, or the desired number of additional plug contacts, must be inserted into its contact cavity, which was initially provided for accommodating the high-current plug contact. The same obviously applies analogously to the mating contact part carrier and the other mating plug contacts.

[0049] Both the high-current plug contact and the high-current mating plug contact can be made of one or more electrically conductive materials, in particular metals, i.e., if necessary, of one or more metals, and respectively have a cable connection area on the cable connection side for mechanically and electrically connecting to each other by plugging and a high-current plug area on the plug-in side.

[0050] The other plug contacts and / or the other mating plug contacts can also be made of one or more electrically conductive materials, in particular metals, but alternatively, depending on the shape and the required elasticity, also of one or more non-electrically conductive materials, such as plastics and, if necessary, of multiple different plastics.

[0051] Preferably, the other plug contacts and the other mating plug contacts are respectively implemented in one piece, in particular integrally. However, a multi-part, in particular multi-piece, implementation is also conceivable.

[0052] In a preferred design, although the additional plug-in contact part and / or the additional mating plug-in contact part each have a plug-in area on the plug-in side for mechanically plugging and connecting to each other, they do not have a cable connection area on the cable connection side. This has the advantage that the additional plug-in contact part and / or the additional mating plug-in contact part can be manufactured at lower cost. Further, this has the advantage that the additional plug-in contact part and / or the additional mating plug-in contact part are implemented particularly stably with respect to their dimensions.

[0053] In a preferred design, the plug-in area of the additional plug-in contact part can be implemented as a contact pin and the plug-in area of the additional mating plug-in contact part can be implemented as a contact sleeve. In particular, the respective contact sleeves of at least one additional mating plug-in contact part can have a plurality of slits, whereby flakes pointing in the plug-in direction are formed in their plug-in area.

[0054] In another preferred embodiment, the contact pin of the plug-in contact part can have a circumferential groove.

[0055] The circumferential groove of the contact pin can further have a plug-in side retaining surface. Preferably, the retaining surface can be oriented substantially perpendicular to the plug-in direction in which the contact pin naturally points, i.e., at an angular relationship between 80° and 120°, particularly at an angular relationship between 85° and 95° or 95° and 105°, and ideally at a right angle of 90° or at an angle of 100°. These values have proven to be particularly suitable in experiments, but obviously other angles can also be meaningful under other boundary conditions.

[0056] Further, the flakes of the mating plug-in contact part pointing in the plug-in direction can have radially inwardly pointing locking hooks at their plug-in side ends, and the locking hooks engage in the circumferential groove of the plug-in contact part in the plugged state.

[0057] The locking hooks can each have a sliding-in bevel and a locking surface, where the locking surface has an angular relationship between 30° and 90°, preferably between 40° and 50° or 55° and 65°, particularly preferably between 42.5° and 47.5° or 57.5° and 62.5°, i.e., at an angle of approximately 45° or 60°, with respect to the plug-in direction.

[0058] A method is used to set the total separation force of a high-current plug connector system. Here, the setting of the preset total separation force is carried out at least by sizing the following parameters:

[0059] - The number of additional plug-in contact parts / additional mating plug-in contact parts;

[0060] - The material of the flakes;

[0061] - The thickness of the flakes;

[0062] - The length of the sheet;

[0063] - The angle of the locking surface of the locking hook of the sheet relative to the insertion direction;

[0064] - The angle of the insertion-side holding surface of the circumferential groove of the contact pin relative to the insertion direction.

[0065] Alternatively or additionally, the setting of the preset total separation force can also be carried out by selecting one or more suitable additional plug-in contact parts and one or more suitable additional mating plug-in contact parts from the group of different other plug-in contact parts and different other mating plug-in contact parts. Description of the Drawings

[0066] Embodiments of the present invention are shown in the drawings and are elaborated in detail below. The drawings show:

[0067] Figure 1a Showing the plug connector housing;

[0068] Figure 1b Showing the modular frame of the equipment;

[0069] Figure 1c 、 Figure 1d Showing other plug-in contact parts;

[0070] Figure 2a Showing the mating plug connector housing;

[0071] Figure 2b Showing the mating modular frame of the equipment;

[0072] Figure 2c Showing other mating plug-in contact parts;

[0073] Figure 3a Showing the other plug-in contact parts enlarged;

[0074] Figure 3b Showing the other mating plug-in contact parts enlarged;

[0075] Figure 4 Showing the other plug-in contact parts and the other mating plug-in contact parts in the inserted state in a sectional view;

[0076] Figure 5a 、 Figure 5b Showing the high-current plug connector system with and without high-current plug contact pairs in a first sectional view;

[0077] Figure 6a 、 Figure 6bThe pluggable high-current connector system with and without pairs of high-current plug contacts is shown in a second sectional view.

[0078] The drawings include partially simplified schematic views. In part, the same reference numerals are used for identical, but not necessarily identical, elements. Different views of the same element may be scaled in different proportions. Directions such as "left", "right", "up" and "down" are to be understood with reference to the respective drawings and may vary with respect to the objects shown in the individual views. Detailed Description

[0079] Figure 1a The connector housing 10 of the plug connector 1 is shown, which in turn is part of the high-current plug connector system shown below (see Figure 5a , Figure 5b and Figure 6a , Figure 6b ). The connector housing 10, which is a sleeve housing, is not necessarily required for the function of the high-current plug connector system. However, in the embodiment shown here, the plug connector 1 and thus also the meaningful safety-technical and protective optional components of the high-current plug connector system are required for the function of the high-current plug connector system. The connector housing 10 is made of plastic and has a cable outlet with a cable lead-out 11 on one side and a rectangular plugging opening 18 on the other side, into which the plugging component 12 shown below can be inserted and latched. In addition, the connector housing 10 has a locking wing 14 at each of its mutually opposite narrow sides for locking with the mating connector housing 20 shown later.

[0080] Figure 1b The above-mentioned plugging component 12 is shown. The plugging component 12 is implemented as a modular frame 120 equipped with plug connector modules 123. Thus, a modular plugging component 12 is involved here. In the present embodiment, three plug connector modules 123 are provided, but in other embodiments, obviously any other number of plug connector modules 123 may also be provided.

[0081] Each plug connector module in the plug connector module 123 has a contact carrier 122, and the contact carrier has two contact cavities 128 each. However, only one of the contact cavities 128 can be seen in the drawing because the other contact cavities are equipped with high-current plug contacts 121. Finally, the two outer contact carriers 122 are completely equipped, that is, in this case, with two high-current plug contacts 121. The middle contact carrier 122 is partially equipped, that is, equipped with high-current mating plug contacts 221, while the last contact cavity 128 remains unoccupied at present for receiving additional plug contacts 100. Obviously, each contact carrier 122 can also have other numbers of contact cavities 128. The contact cavities 128 of the contact carrier 122 are implemented in the same shape as each other.

[0082] Figure 1c and Figure 1d shows the above-mentioned additional plug contact 100, which is arranged to be introduced into the last still un-equipped contact cavity 128. The additional plug contact can be received in the contact cavity 128 and can be held therein by the contact carrier 122, but is particularly distinguished from the above-mentioned high-current plug contact 121 in that although the high-current plug contact has a holding area 108, it is solidly implemented, so that the additional plug contact 100 does not have a cable connection area.

[0083] The additional plug contact 100 also has a plugging area implemented as a contact pin 101. The contact pin 101 has a surrounding groove 106 with a plugging-side holding surface 107, and the plugging-side holding surface is particularly well visible and marked in the enlarged view in Figure 1d and is marked.

[0084] Figure 2a shows the mating plug connector housing 20 of the mating plug connector 2, which together with the above-mentioned plug connector 1 is a component of the high-current plug connector system. The mating plug connector housing 20, which is a sleeve housing, is not necessarily required for the function of the high-current plug connector system, but in the embodiment shown here, the mating plug connector 2 and thus the meaningful safety-technical and protective optional component of the high-current plug connector system are required for the function of the high-current plug connector system. The mating plug connector housing 20 is made of plastic, has a cable outlet with a cable lead-out portion 21 on one side and a rectangular plugging opening 28 on the other side, and the mating plug connector assembly 22 shown below can be inserted and latched into the rectangular plugging opening. In addition, the mating plug connector housing 20 has two latching pins 24 each for latching with the two locking wings 14 of the plug connector housing 10 at its two longitudinal sides.

[0085] Figure 2b Shows the above-mentioned mating connector assembly 22. The mating connector assembly 22 is implemented as a modular frame 220 equipped with a mating connector module 223. Therefore, a modular mating connector assembly 22 is involved here. In this embodiment, there are three mating connector modules 223, but in another embodiment, it is obvious that any other number of mating connector modules 223 can also be provided.

[0086] Each of the mating connector modules 223 in the mating connector module has a mating contact carrier 222, and the mating contact carrier has two mating contact cavities 228 each. However, only one of the mating contact cavities 228 can be seen in the drawing because the other mating contact cavities are equipped with high-current mating plug contacts 221. Finally, the two outer mating contact carriers 222 are completely equipped, that is, in this case, they are equipped with two high-current mating plug contacts 221. The middle mating contact carrier 222 is only partially equipped, that is, equipped with high-current mating plug contacts 221, and the last mating contact cavity 228 remains unoccupied at present for accommodating additional mating plug contacts 200. Obviously, each of the mating contact carriers 222 can also have other numbers of mating contact cavities 228. The mating contact cavities 228 of the mating contact carrier 222 are implemented in the same shape as each other.

[0087] Figure 2c Shows the above-mentioned additional mating plug contact 200, and the mating contact carrier is arranged to be introduced into the yet-to-be-equipped mating contact cavity 228. The above-mentioned additional mating plug contact can be accommodated in the mating contact cavity 228 and can be held therein by the mating contact carrier 222, but is particularly distinguished from the above-mentioned high-current mating plug contact 221 in that although the additional mating plug contact has a holding area 208, it is solidly implemented so that the additional mating plug contact 200 does not have a cable connection area.

[0088] The additional mating plug contact 200 also has a plugging area implemented as a contact sleeve 201. The contact sleeve 201 has a plurality of slits 206, and through the plurality of slits, the thin sheet 209 is provided with end-side, inwardly directed locking hooks 207 (visible in Figure 3b )

[0089] Figure 3a The additional plug contact 100 is shown enlarged. The holding surface 107 surrounding the groove 106 is blocked here.

[0090] Figure 3bThe enlarged view shows additional mating plug-in contact parts 200. Through the sectional view, in the upper right of the drawing, the locking hook 207 with the insertion slope 2072 and the locking surface 2071 inclined relative to the insertion direction is clearly visible.

[0091] Therefore, from Figure 3a and 3b it is clearly known to those skilled in the art that the single separation force is significantly higher than the single insertion force. Finally, during insertion, the insertion chamfer (not marked) shown on the right in Figure 3a slides along the insertion slope 2072 of the additional mating plug-in contact part 200, and its thin plates 209 are bent separately from each other on most of the insertion path corresponding to the shape of the chamfer.

[0092] On the contrary, the following part of the extraction path is significantly smaller, in which the retaining surface 107 of the additional plug-in contact part 100 presses the thin plates 209 of the additional mating contact part 200 separately from each other via their corresponding locking surfaces 2071 when extracting from the additional mating contact part 200. However, the additional plug-in contact part must apply at least the same mechanical energy on this short section according to the energy acquisition scheme. From this alone, in addition to the increased friction effect, the single separation force is already significantly higher than the above single insertion force, because the single insertion force finally provides a significantly longer section to apply the same mechanical tension energy of the thin plate.

[0093] Figure 4 The additional plug-in contact part 100 and the additional mating plug-in contact part 200 in the inserted state are shown in the sectional view. It can be easily seen that the locking hook 207 engages behind the retaining surface 107 (not marked here) of the groove 106 by means of its locking surface 2071 inclined relative to the insertion direction. Therefore, a corresponding single separation force must be applied for separation.

[0094] Figure 5a and Figure 5b and 6a and Figure 6b show a high-current plug-in connector system in the inserted state, which has a plug-in connector 1 and a mating plug-in connector 2, with and without high-current plug-in contact pairs in two different sectional views, and the high-current plug-in contact pairs are composed of high-current plug-in contact parts 121 and high-current mating plug-in contact parts 221.

[0095] In Figure 5a and Figure 5b it is particularly clearly visible how the thin plates 209 of the additional mating plug-in contact part 200 completely surround the contact pins 101 of the additional plug-in contact part 100 in the area of its groove 106. In Figure 6a and Figure 6bIt can be clearly seen how the latching hook 207 of the wafer 209 engages into the groove 106.

[0096] It is further clearly visible that the contact cavities 128 are implemented in the same type for each other, regardless of whether the high-current plugging contact part 121 or another plugging contact part 100 is inserted therein. It is also visible that the mating contact cavities 228 are implemented in the same type for each other, regardless of whether the high-current mating plugging contact part 221 or another mating plugging contact part 200 is inserted therein.

[0097] List of reference numerals

[0098] 1 Plug connector

[0099] 10 Plug connector housing

[0100] 11 Cable lead-out part

[0101] 12 Plug connector assembly

[0102] 18 Plugging opening

[0103] 121 High-current plugging contact part

[0104] 122 Contact part carrier

[0105] 123 Plug connector module

[0106] 128 Contact cavity

[0107] 100 Another plugging contact part

[0108] 101 Plugging area, contact pin

[0109] 106 Groove

[0110] 107 Holding surface

[0111] 108 Holding area

[0112] 2 Mating plug connector

[0113] 20 Mating plug connector housing

[0114] 21 Cable lead-out part

[0115] 22 Mating plug connector assembly

[0116] 28 Plugging opening

[0117] 221 High-current mating plugging contact part

[0118] 222 Mating contact part carrier

[0119] 223 Mating plug connector module

[0120] 228 Mating contact cavity

[0121] 200 additional mating plug contacts

[0122] 201 Plug-in area, contact sleeve

[0123] 206 Gap

[0124] 207 Latching hook

[0125] 2071 Latching surface

[0126] 2072 Inclined sliding surface

[0127] 208 Retaining area

[0128] 209 Lamina

Claims

1. A high-current plug connector system having a plug connector (1) and a mating plug connector (2), the plug connector and the mating plug connector being capable of being plugged into each other and of being separated from each other under a total separating force, wherein the plug connector (1) has a plurality of high-current plug contact parts (121) of the same type with respect to each other, and wherein the mating plug connector (2) has a plurality of high-current mating plug contact parts (221) capable of being plugged into the high-current plug contact parts (121), wherein in the plugged state, each high-current plug contact part among the high-current plug contact parts (121) is mechanically and conductively connected to one of the high-current mating plug contact parts among the high-current mating plug contact parts (221) to form one high-current plug contact pair for transmitting electrical energy. Characterized in that, the plug connector (1) has at least one additional plug contact part (100) and the mating plug connector (2) has at least one additional mating plug contact part (200), wherein the at least one additional plug contact part (100) and the at least one additional mating plug contact part (200) can be plugged into each other under the application of a single plugging force and can be separated from each other again under the application of a single separating force in the plugged state so as to be jointly configured for generating a preset value of the total separating force, wherein the single separating force is at least 1.5 times the single plugging force.

2. The high-current plug connector system according to claim 1, Characterized in that, the additional plug contact part (100) and the additional mating plug contact part (200) are latched with each other in the plugged state.

3. The high-current plug connector system according to any one of the above claims, Characterized in that, each high-current plug contact pair is designed for transmitting a current intensity of at least 10 A ("ampere"), preferably at least up to 20 A, particularly preferably at least up to 40 A, especially at least up to 60 A, for example at least up to 80 A and especially even at least up to 100 A or even more in the plugged state.

4. The high-current plug connector system according to any one of the above claims, Characterized in that, the single separating force is at least 75 N ("newton"), for example at least 85 N and preferably even 97 N and especially even more, for example more than 100 N and, if necessary, also 110 N and more, that is, for example 120 N and more.

5. The high-current plug connector system according to any one of the above claims, Characterized in that, the plug connector (1) has at least one contact part carrier (122), the at least one contact part carrier being formed of an electrically insulating material and, in one contact part carrier or in a plurality of contact part carriers in total, contact cavities (128) being respectively provided for each high-current plug contact part among the high-current plug contact parts (121) and also for each additional plug contact part among the additional plug contact parts (100), and further The mating plug connector (2) has at least one mating contact part carrier (222) made of an electrically insulating material. In one mating contact part carrier or in a plurality of mating contact part carriers in total, for each high-current mating plug contact part among the high-current mating plug contact parts (221) and also for each further mating plug contact part among the further mating plug contact parts (200), a mating contact cavity (228) is respectively provided. And the contact cavities (128) of the plug connector (1) are implemented to have the same shape with each other, and further the mating contact cavities (228) of the mating plug connector (2) are implemented to have the same shape with each other.

6. The high-current plug connector system according to claim 5, characterized in that the at least one contact part carrier (122) has a cable connection side and a plug side opposite to the cable connection side, and the contact cavity (128) is implemented as a through-opening that connects the cable connection side and the plug side, and the at least one mating contact part carrier (222) has a mating cable connection side and a mating plug side opposite to the mating cable connection side, and the mating contact cavity (228) is also implemented as a through-opening that connects the mating cable connection side and the mating plug side.

7. The high-current plug connector system according to any one of the above claims, characterized in that the high-current plug contact part (121) and one or more of the further plug contact parts (100) are respectively arranged in and held in one of the contact cavities (128) of the plug connector (1), and the high-current mating plug contact part (221) and one or more of the further mating plug contact parts (200) are respectively arranged in and held in one of the mating contact cavities (228) of the mating plug connector (2).

8. The high-current plug connector system according to any one of the above claims, characterized in that not only the high-current plug contact part (121) but also the high-current mating plug contact part (221) are made of one or more conductive materials, in particular one or more metals, and respectively have a cable connection area on the cable connection side and a high-current plug area on the plug side for mechanically and conductively connecting with each other in an inserted manner, and further the further plug contact parts (100) and / or the further mating plug contact parts (200) are made of one or more conductive materials, in particular metals or are made of one or more non-conductive materials, such as plastics, and respectively have an insertion area (101, 201) on the plug side for mechanically connecting with each other in an inserted manner, but do not have a cable connection area on the cable connection side.

9. The high-current plug connector system according to claim 8, characterized in that The plugging area of the additional plugging contact part (100) is implemented as a contact pin (101), and the plugging area of the additional mating plugging contact part (200) is implemented as a contact sleeve (201).

10. The high-current plug connector system according to claim 9, characterized in that the contact sleeve (201) of the at least one additional mating plugging contact part (200) has a plurality of slits (206), thereby forming lamellae (209) pointing in the plugging direction.

11. The high-current plug connector system according to claim 10, characterized in that the contact pin (101) of the additional plugging contact part (100) has a circumferential groove (106).

12. The high-current plug connector system according to claim 11, characterized in that the contact pin (101) points in the plugging direction and the circumferential groove (106) has a plugging-side holding surface (107), and the plugging-side holding surface is oriented substantially perpendicular to the plugging direction, that is, at an angular relationship between 80° and 100°, especially at an angular relationship between 85° and 95° or 95° and 105°, and ideally at a right angle of 90°.

13. The high-current plug connector system according to claim 12, characterized in that the lamellae (209) of the additional mating plugging contact part (200) have radially inwardly pointing latching hooks (207) at their plugging-side ends, and the latching hooks engage into the circumferential groove (106) of the additional plugging contact part (100) in the plugged state.

14. The high-current plug connector system according to claim 13, characterized in that each of the latching hooks (207) has a sliding-in inclined surface (2072) and a latching surface (2071), and the latching surface (2071) has an angular relationship between 30° and 90°, preferably between 40° and 50° or 55° and 65°, particularly preferably between 42.5° and 47.5° or 57.5° and 62.5° with respect to the plugging direction, that is, for example, at an angle of 45° or at an angle of 60°.

15. The high-current plug connector system according to any one of the above claims, characterized in that the high-current plug connector system additionally has groups of different additional plugging contact parts (100) and different additional mating plugging contact parts (200), and the different additional plugging contact parts and different additional mating plugging contact parts generate different individual separation forces when connected to each other and can be selectively inserted into the contact part carrier (122) of the plug connector (1) or the mating contact part carrier (222) of the mating plug connector (2) to generate the preset total separation force.

16. A method for setting the total separation force of the high-current plug connector system according to any one of claims 14 to 15, wherein the setting of the preset total separation force is carried out at least by sizing the following parameters: - The number of said additional plug-in contact parts (100) / additional mating plug-in contact parts (200); - The material of said thin sheet (209); - The thickness of said thin sheet (209); - The length of said thin sheet (209); - The angle of the locking surface (2071) of the locking hook (207) of said thin sheet (209) relative to the plugging direction; - The angle of the holding surface (107) on the plugging side of the circumferential groove (106) of said contact pin (101) relative to the plugging direction.

17. A method for setting the total separation force of a high-current plug connector system according to claim 15, wherein the setting of the preset total separation force is carried out by selecting one or more suitable additional plug-in contact parts (100) and one or more suitable additional mating plug-in contact parts (200) from said group of different additional plug-in contact parts (100) and different additional mating plug-in contact parts (200).

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