Plug connector
By designing the contact element structure of the plug connector and using material locking and welding connections, the stability problem of the electrical connection between the motor and the converter device was solved, enabling reliable current flow without printed circuit boards, simplifying the connection process and reducing costs.
Patent Information
- Application Number
- CN202510935792.X
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Priority Date
- 2024-07-08
- Filing Date
- 2025-07-08
- Publication Date
- 2026-01-09
AI Technical Summary
In the prior art, it is difficult to achieve stable and reliable current flow in the electrical connection between the motor and the converter device, especially in the connection between the stator winding and the AC voltage interface, which requires additional components such as printed circuit boards to realize the electrical and mechanical connection.
A plug connector is designed, which adopts a planar section and slotted section structure of the first and second contact elements. It realizes the electrical connection between the motor and the converter through material locking connection and welding or brazing connection, without the need for an additional printed circuit board.
This achieves mechanical stability and electrical connection between the motor and the converter, increases the contact area, simplifies the connection process, reduces costs, and improves the reliability and stability of the connection.
Smart Images
Figure CN121307544A_ABST
Abstract
Description
TECHNICAL FIELD
[0001] The invention relates to a plug-in connector which is configured for forming a plug-in connection with a mating plug-in connector. BACKGROUND
[0002] For producing an electrical connection, plug-in connector assemblies can be used in which a device which needs to be supplied with a signal and / or an electrical current has a plug-in connector whose contact elements have to be connected with a corresponding interface or line in the device. For example, an electrical connection is needed between a stator of an electrical machine and an alternating voltage interface of an inverter device for operating and driving the electrical machine, wherein a plug-in connector can be arranged on the housing of the electrical machine whose contact elements are connected with the stator winding. For example, the plug-in connector can have a printed circuit board inside which is connected with the contact elements of the plug-in connector on the one hand and with the stator winding on the other hand, wherein the contact elements and the stator winding are connected by means of the conductive tracks of the printed circuit board. SUMMARY
[0003] According to the invention, a plug-in connector having the features of the independent claim is proposed. Advantageous designs are the subject matter of the dependent claims and the following description.
[0004] The invention relates to a plug-in connector which can be configured, for example, for connecting a phase winding of an electrical machine and an alternating voltage interface of an inverter device. The plug-in connector is configured for forming a plug-in connection with a mating plug-in connector and has a plug-in connector housing, a first contact element and a second contact element. The first contact element is configured to be electrically contacted by the second contact element. The second contact element is configured to be electrically contacted by a mating plug-in connector contact element of the mating plug-in connector. The first contact element has a first planar section and a first slotted section directly adjoining the first planar section. The second contact element likewise has a second planar section and a second slotted section directly adjoining the second planar section. The first and second contact elements are connected in such a way that the first planar section is inserted into the second slotted section and the second planar section is inserted into the first slotted section.
[0005] The plug-in connector can enable the production of an electrical connection, in particular between an electrical machine, for example an electric motor or a generator, and a corresponding alternating voltage interface of an inverter device. Here, the alternating voltage interface can be designed as three-phase, wherein each phase is connected with a corresponding phase winding of the electrical machine by means of the proposed plug-in connector. Thus, the plug-in connector can have, for example, three first contact elements and three second contact elements.
[0006] The or each first and second contact element can here bring about the generation of an electrical connection between the AC voltage interface and the electric machine by electrically connecting the first and second contact elements. The contact elements are here preferably composed of an electrically conductive material, in particular a metal, such as copper, a copper alloy or aluminum.
[0007] The first and second contact elements each have a planar section and a slotted section directly adjoining the planar section. The first and second contact elements can thus be connected in such a way that the planar section of one contact element is inserted into the slotted section of the other contact element. By this connection, a large tolerance compensation is formed, which is advantageous for many application cases.
[0008] The connection between the two contact elements can be designed to be material-locked and to have as large a contact area as possible. A mechanically stable connection can thus be brought about between the two contact elements, so that a constant current flow between the AC voltage interface and the electric machine, for example, can be ensured.
[0009] The first contact element can be designed, for example, in such a way that a first slotted section is formed at one end in the main extension direction of the first contact element. The first contact element can here have a rectangular cross section, preferably with rounded corners. The second contact element can be designed as a plate and have a second slotted section. The slotted sections of the two contact elements can further be designed to fit flush with one another, so that in particular the slotted inner surface of the first contact element flushly surrounds the plate-shaped second contact element. A mechanically and electrically stable connection can thus be brought about between the two contact elements.
[0010] The section of the first contact element facing the second contact element, which is separated by the slotted section, can further be designed to taper in the main extension direction. The connection process between the two contact elements can thus be simplified, because in particular the first contact element can be guided by means of the tapered section so that it surrounds the second contact element in a predefined arrangement.
[0011] Furthermore, the proposed plug-in connector allows a connection to be brought about between the electric machine and the AC voltage interface of the inverter device, for example, without additional components being required, in particular without a printed circuit board for electrically and mechanically connecting the contact elements.
[0012] In one embodiment, the first slotted section has a first slotted end face and the second slotted section has a second slotted end face. The first slotted end face here rests on the second slotted end face.
[0013] The two slotted sections are here in particular arranged to fit into one another as maximally as possible. The two slotted end faces of the two contact elements can here be connected, for example, by means of a solder or brazing connection (Schweiβ- oder ) so that an electrical and mechanical connection between the two contact elements can be produced.
[0014] Furthermore, the other slotted inner surfaces of the two contact elements can also be designed to lie against one another, so that, in particular, no gap is present between the two contact elements. A stable mechanical connection is thereby formed between the two contact elements, which, for example, allows a continuous current flow.
[0015] In another embodiment, the first slotted section has at least one first slotted inner surface and the second slotted section has at least one second slotted inner surface. Here, the slotted inner surfaces and / or the slotted end faces of the two contact elements can each be at least regionally coated.
[0016] By coating the slotted inner surfaces, the electrical connection between the contact elements can be improved, for example by cleaning the surfaces of the contact elements and / or removing potential oxide layers by applying the coating, so that, in particular, the connection produced by soldering between the contact elements can be improved. Furthermore, a flux can be applied to the slotted inner surfaces, so that the connection produced by brazing between the contact elements is improved. The use of a flux, in particular, allows a uniform distribution of the solder between the two contact elements.
[0017] In another embodiment, a material-locked connection is present between the first slotted section and the second planar section and between the first planar section and the second slotted section.
[0018] Here, as before, the second contact element can be designed, for example, as a plate. The first contact element can have a rectangular cross section, wherein the first slotted section is arranged at one end in the main extension direction of the first contact element. The first contact element can additionally have a tapered section on the side facing the second contact element, so that the first contact element can be guided to surround the second contact element in a preferred arrangement. This, in particular, allows a simple connection process between the contact elements. By the material-locked arrangement according to this embodiment, the electrical connection can also be improved, since, in particular, the cross-sectional area of the connection is increased. Furthermore, the material-locked connection can contribute to a reliable mechanical connection of the two contact elements.
[0019] In another embodiment, a material-locked connection can be present between the first slotted section and the second slotted section.
[0020] This arrangement is particularly advantageous, since according to the above-described embodiment the electrical and mechanical connection between the two contact elements can be improved. Since in this embodiment the slotted sections are arranged in a mutually interlocking manner, the relative position of the two contact elements is also predetermined, so that the connection of the contact elements can be produced in a reproducible and reliable manner. Since the number of degrees of freedom in space is reduced, the connection between the two contact elements in this embodiment is particularly mechanically stable, so that the reliability of the electrical connection can be improved, among other things.
[0021] The material-bonded connection can be produced, for example, by means of a soldering, welding or adhesive connection, or by any combination of the said connection methods. By means of the said connection methods, the contact elements can be connected in a mechanically stable manner, so that the current flow between the two contact elements can be reliably ensured. By means of a mechanically stable connection, possible wear of the connection, for example as a result of mechanical friction between the contact elements, can be reduced. In particular by means of soldering and welding connections, a mechanically stable and at the same time electrically conductive connection can be produced. Furthermore, it is also possible to use electrically conductive adhesives, for example by introducing electrically conductive elements into the adhesive. The connection produced by means of soldering, welding and / or adhesive is also cost-effective and easy to implement.
[0022] In another embodiment, the first and / or second contact element can be produced as a stamped part or a stamped and bent part, or by means of a forming process on a cylindrical wire section. Thereby, the contact elements can be produced simply and cost-effectively.
[0023] In another embodiment, the plug connector has a securing device, wherein the first and / or second contact element is secured by the securing device in the plug connector housing.
[0024] By means of the securing in the plug connector housing, it can be ensured or improved, for example, that during the production of the plug connector the slotted sections interlock with one another, in particular when the plug connector has a plurality of first and second contact elements, respectively.
[0025] The securing device can be produced, for example, by injection molding (Eingieβen, injection molding) of the proposed plug connector with at least one material from the group consisting of polyamide (PA), polyethylene (PE), polypropylene (PP), polyvinyl chloride (PVC) and acrylonitrile-butadiene-styrene copolymer (ABS).
[0026] In another embodiment, the securing device can have a guide channel with an insertion opening for accommodating the first or second contact element. Here, the guide channel can taper from the insertion opening.
[0027] This embodiment makes the connection process of the two contact elements when manufacturing the plug connector easier, since the two contact elements can be brought into a predefined relative position by means of the guiding element, even if there are, for example, production-induced or necessary geometric tolerances. The fixing device thus allows a repeatable arrangement of the contact elements, in particular relative to one another, so that the reliability of the mechanical and electrical connection between the contact elements can be improved.
[0028] In another embodiment, the fixing device can be an integral part of the plug connector housing or a part of another element of the plug connector.
[0029] By the integral construction of the fixing device, it can be designed to be mechanically particularly stable. In the embodiment in which the fixing device is a part of another element of the plug connector, for example, the geometric complexity of the fixing device can be reduced, since only fewer geometric limitations, for example, resulting from the shape of the plug connector housing, have to be taken into account. By the reduced complexity, a simpler and less costly manufacture can be achieved.
[0030] In another embodiment, the second contact element can be materially embedded in the plug connector housing.
[0031] This can be achieved, for example, by injection molding or overmolding the second contact element cost-effectively and simply. Thereby, the second contact element can be fixed reliably and mechanically stably in the plug connector.
[0032] In another embodiment, the plug connector can be designed as an embedded plug. Here, the plug connector can be designed to produce a connection with an electric motor.
[0033] As already mentioned, the plug connector can be designed, for example, for connecting the phase windings of an electric motor and the AC voltage interface of an inverter device.
[0034] The plug connector can also be used to produce an electrical connection between a heating, ventilation or air conditioning device (HLK or HVAC) or an electric motor arranged therein and a corresponding power supply. BRIEF DESCRIPTION OF DRAWINGS
[0035] Figure 1a - c shows a schematic embodiment of a plug connector according to the application in perspective view, cross-sectional view and longitudinal sectional view.
[0036] Figure 2a - b shows a schematic embodiment of a plug connector according to the application with a fixing device.
[0037] Figure 3A partial view of a schematic embodiment of a plug-in connector according to the application is shown, wherein the second contact element has a bend. DETAILED DESCRIPTION
[0038] Figure 1a An embodiment 100 of the proposed plug-in connector is shown schematically in perspective view. The plug-in connector 100 has three first contact elements 101a-c, which can be connected with an electric machine, and two second contact elements 102a-b, to which an alternating voltage interface of a converter device can be connected respectively. A further second contact element is not shown, but present.
[0039] Figure 1b In a cross-sectional view along the x-y plane defined in Figure 1a An embodiment 100 of the proposed plug-in connector is shown schematically in perspective view. The plug-in connector 100 has three first contact elements 101a-c, which can be connected with an electric machine, and two second contact elements 102a-b, to which an alternating voltage interface of a converter device can be connected respectively. A further second contact element is not shown, but present. Figure 1a The first contact element 101b and the second contact element 102a of the plug-in connector 100 shown.
[0040] Figure 1c In a longitudinal cross-sectional view along the y-z plane defined in Figure 1a The first contact element 101b and the second contact element 102a of the plug-in connector 100 shown. Figure 1a The first contact element 101b and the second contact element 102a of the plug-in connector 100 shown.
[0041] Figure 1a to 1c will be described together in the following.
[0042] The first contact elements 101a-c have a rectangular shape with rounded corners. At the end facing the second contact elements 102a-b, the first contact elements 101a-c have a first slotted section 104 respectively along the respective main extension direction. Thus, the first contact elements have a first planar section 103 and a slotted section 104 directly adjoining the first planar section 103 respectively.
[0043] The end or tip of the first slotted section 104 facing the second contact elements 102a-b can have a tapering 105a-b respectively, for example in the form of a bevel.
[0044] Furthermore, each first slotted section 104 has one first slotted end face 108a and two first slotted inner surfaces 109a-b.
[0045] The second contact elements 102a-b likewise have a second planar section 106 and a second slotted section 107 respectively. In the embodiment shown, the second contact elements 102a-b are additionally curved several times along different spatial axes. Each second slotted section 107 has one second slotted end face 108b and two second slotted inner surfaces 110a-b.
[0046] In the embodiment 100 shown, two first contact elements 101b-c are each connected with one second contact element 102a-b. Here, the first and second contact elements 101b-c, 102a-b are each arranged such that the first slotted end face 108a of the first contact element 101b-c lies against the second slotted end face 108b of the second contact element 102a-b. This is shown in more detail in Figure 1b and Figure 1c .
[0047] The second contact element 102a is connected with the first contact element 101b in such a way that the first slotted end face 108a of the first contact element 101b and the second slotted end face 108b of the second contact element 102a are connected. In this embodiment, the first slotted inner surfaces 109a-b of the first contact element 101b are not connected with the second contact element 102a or the second slotted inner surfaces 110a-b.
[0048] Figure 2a A perspective sectional view of a schematic illustration of a further embodiment 200 of the proposed plug-in connector is shown.
[0049] The embodiment 200 shown comprises two first contact elements 201a-b and one second contact element 202. Here, the first and second contact elements 201a-b, 202 can be designed, in particular, as contact elements 101a-c, 102a-b shown in Figure 1a -c. The first contact element 201a is connected with the second contact element 202 along the respective slotted end faces 108a-b, similar to the illustration in Figure 1a -c.
[0050] Furthermore, the second contact element 202 is integrated into a securing device 204, which is designed as an integral part of the plug-in connector housing 203. The first contact elements 201a-b can each be guided through a guide channel in the securing device 204, such that, in particular, the first contact element 201a can be positioned correctly relative to the second contact element 202.
[0051] The securing device 204 also has a guide channel, through which the first contact element 201a passes. The guide channel here has an insertion opening, from which the guide channel tapers.
[0052] Figure 2b An embodiment 200' of the proposed plug-in connector is shown schematically in a sectional view. Here, the securing device 208 is formed in an additional element 207, which is connected with the plug-in connector housing 206. In addition to this, the securing device 208 corresponds functionally to the securing device 204.
[0053] Figure 3 A partial view of one exemplary embodiment 300 of the proposed plug connector is shown. Here, a first contact element 301 is connected with a second contact element 302, corresponding to Figure 1a - c and Figure 2a In this embodiment 300, the second contact element 302 has a bend 303, so that the second contact element 302 can accommodate, inter alia, the geometrical requirements of the plug connector or plug connector housing 203, 206.
Claims
1. Plug connector (100, 200, 200', 300), which is configured for forming a plug connection with a mating plug connector, the plug connector (100, 200, 200', 300) having a plug connector housing (203, 206), a first contact element (101a-c, 201a-b, 205a-b, 301) and a second contact element (102a-b, 202, 302), wherein the first contact element (101a-c, 201a-b, 205a-b, 301) being configured to be electrically contacted by the second contact element (102a-b, 202, 302), wherein the second contact element (102a-b, 202, 302) is configured to be electrically contacted by a mating plug connector contact element of a mating plug connector, wherein the first contact element (101a-c, 201a-b, 205a-b, 301) has a first planar section (103) and a first slotted section (104) directly adjoining the first planar section (103), wherein the second contact element (102a-b, 202, 302) has a second planar section (106) and a second slotted section (107) directly adjoining the second planar section (106), wherein the first contact element (101a-c, 201a-b, 205a-b, 301) and the second contact element (102a-b, 202, 302) are connected in such a way that the first planar section (103) is inserted into the second slotted section (107) and the second planar section (106) is inserted into the first slotted section (104).
2. Plug connector (100, 200, 200', 300) according to claim 1, wherein The first slotted section (104) has a first slotted end face (108a), the second slotted section (107) has a second slotted end face (108b), and the first slotted end face (108a) rests on the second slotted end face (108b).
3. Plug connector (100, 200, 200', 300) according to any one of the preceding claims, wherein The first slotted section (104) has at least one first slotted inner surface (109a-b), the second slotted section (107) has at least one second slotted inner surface (110a-b), and the at least one first slotted inner surface (109a-b) and / or the at least one second slotted inner surface (110a-b) and / or the first slotted end face (108a) and / or the second slotted end face (108b) are at least regionally coated.
4. Plug connector (100, 200, 200', 300) according to any one of the preceding claims, wherein There is a material-locked connection between the first slotted section (104) and the second planar section (106), and there is a material-locked connection between the first planar section (103) and the second slotted section (107).
5. Plug connector (100, 200, 200', 300) according to any one of the preceding claims, wherein There is a material-locked connection between the first slotted section (104) and the second slotted section (107).
6. Plug connector (100, 200, 200', 300) according to any one of the preceding claims, wherein The first contact element (101a-c, 201a-b, 205a-b, 301) and the second contact element (102a-b, 202, 302) are material-locked connected.
7. Plug connector (100, 200, 200', 300) according to any one of the preceding claims, wherein The first contact elements (101a-c, 201a-b, 205a-b, 301) and / or the second contact elements (102a-b, 202, 302) are manufactured as stamped or stamped and bent parts, or by means of a forming process on a cylindrical wire section.
8. Plug connector (100, 200, 200', 300) according to any one of the preceding claims, wherein The plug connector (100, 200, 200', 300) has a securing device (203, 208), wherein the first contact elements (101a-c, 201a-b, 205a-b, 301) and / or the second contact elements (102a-b, 202, 302) are secured by the securing device (204, 208) in the plug connector housing (203, 206).
9. Plug connector (100, 200, 200', 300) according to claim 8, wherein The securing device (204, 208) has a guide channel with an insertion opening for accommodating the first contact elements (101a-c, 201a-b, 205a-b, 301) or the second contact elements (102a-b, 202, 302), and the guide channel tapers from the insertion opening.
10. Plug connector (100, 200, 200', 300) according to any one of the preceding claims, wherein The securing device (204, 208) is an integral part of the plug connector housing (203, 206), or the securing device (204, 208) is part of a further element (207) of the plug connector (100, 200, 200', 300).
11. Plug connector (100, 200, 200', 300) according to any one of the preceding claims, wherein The second contact elements (102a-b, 202, 302) are materially embedded in the plug connector housing (203, 206).
12. Plug connector (100, 200, 200', 300) according to any one of the preceding claims, wherein The plug connector (100, 200, 200', 300) is configured as a flush-mounted plug, and the plug connector (100, 200, 200', 300) is configured for a connection to an electric motor.