Touch-proof connector, end cap and charging socket

Abstract

A touch-proof connecting element (80) comprising: a conductive body section (82) with a tip (86) at one end; and a non-conductive end cap (84) attached to the tip (86), the end cap (84) comprising a front end (92) and a coupling end (94), the coupling end (94) having an opening (100) shaped to fit over the tip (86), the opening (100) of the coupling end (94) having a relief (104) to snap into a groove (106) formed within the tip (86), characterized in that the end cap (84) has at least one passage (124, 126) oriented transversely to the opening (100) to allow movement of the relief (104) into the groove (106).

Description

TECHNICAL AREA

[0001] The present invention relates to a touch-proof connecting element, an end cap for use with a conductive connecting element and a charging socket for use in a vehicle to accommodate a connecting element arrangement.

[0002] It refers to electrical connecting elements, such as electrical connecting elements of the type with an insulated tip that is connected to a conductive body section. BACKGROUND

[0003] Electrical connectors are used in numerous environments to facilitate the electrical connection of one or more components. Electrical connectors can be used within a socket to facilitate the electrical connection to a device designed to be received within the socket.

[0004] DE 44 00 555 A1 describes a connector consisting of a socket and a plug. The plug has at least one contact pin and at least one shield surrounding the contact pins. The socket has at least as many contact sockets as there are contact pins in the plug. The contact sockets are surrounded by a shield.

[0005] US Patent 2,537,370 A discloses an electrical plug-socket arrangement comprising a plug and a socket. The plug has a pair of parallel, spaced-apart pins that can be inserted into corresponding slots in the socket. An insulating cover is fitted over the pins.

[0006] US 2011 0 053 404 A1 also describes a plug and socket. The plug housing contains a tube. The tube is positioned at a distance from a conductive part of the plug. This distance is chosen so that a finger cannot be inserted between the plug and the tube.

[0007] US 7,470,154 B2 discloses a connector with four terminals evenly spaced around a central point. A housing supports the terminals and includes a cover. At least two of the terminals have insulating coating layers.

[0008] A plug with an insulating housing is known from GB 2 323 221 A. GB 2 323 221 A further discloses conductive connecting pins of a plug that extend into a tubular opening. A socket can receive the plug. The socket is insulated by the housing of the socket and by the housing of the plug.

[0009] DE 197 14 693 A1 relates to a plug-in connector unit of an end-face coupling type and a coaxial connector equipped with this unit. The plug-in connector unit has an insulator that projects axially from the respective end face of the first plug-in connector and the second plug-in connector to prevent contact with the respective end face by a user's finger. The insulators are arranged offset from each other around the longitudinal axis of the respective plug-in connector.

[0010] JP S60-145 560 U describes a terminal block. The terminal block has a guide made of heat-resistant resin material, which is screwed onto a thread formed on the circumference of a tip.

[0011] JP S56-9 683 U also describes a plug connection. To accommodate a plug, this connector has a constriction in the socket. When the plug is inserted into the socket, the constriction is pushed outwards and encloses the plug.

[0012] DE 36 02 797 A1 describes a contact pin for an electrical connector. The connector features a spring-loaded pin receptacle. To suppress contact bounce, the surface of the contact pin at its end section, which covers the bounce area, is made of electrically insulating material.

[0013] DE 199 53 663 A1 relates to a terminal block, for example a plug pin, used in connectors for a variety of electrical devices. The plug pin comprises a terminal body made of an electrically conductive metal and a stop body made of an insulating resin.

[0014] If the connector inside the socket is exposed and a person accidentally touches the connector while it is energized, the person could make an unwanted electrical connection. Therefore, the present invention aims to configure the connector to limit the likelihood that a person or device could accidentally touch the connector in a way that would likely create an electrical connection. SUMMARY

[0015] The problem underlying the invention is solved by a connecting element according to claim 1, an end cap according to claim 7 and a charging socket according to claim 9. Advantageous further developments are the subject of the dependent patent claims.

[0016] In general, the present invention describes a touch-proof connecting element with an insulating end cap that is attached to a conductive body section to prevent accidental contact with the conductive body section.

[0017] The invention relates to a touch-proof connecting element comprising: a conductive body section with a tip at one end; and a non-conductive end cap attached to the tip.

[0018] The end cap comprises a front end and a coupling end, the coupling end having an opening shaped to fit over the tip.

[0019] The coupling end has a relief shape to snap into a groove contained within the tip.

[0020] An optional aspect of the present invention provides that the end cap includes several alignment projections outside the relief to facilitate centering the coupling end relative to the tip. An optional aspect of the present invention provides that the end cap includes at least one passage oriented transversely to the opening to facilitate movement of the relief into the groove.

[0021] An optional aspect of the present invention provides that the tip comprises several prongs which are shaped to engage with the opening within the end cap.

[0022] An optional aspect of the present invention provides that the body section comprises a recessed end and a non-recessed end, the non-recessed end being shaped to form the tip. An optional aspect of the present invention provides that a front end of an outer section of the end cap widens outwards to form a coupling end, the coupling end engaging with a surface of the body section contained behind the tip.

[0023] An optional aspect of the present invention provides that an outer diameter of the coupling end is approximately equal to an outer diameter of the body section near the coupling end in order to create a flush outer surface at a boundary between the end cap and the body section.

[0024] The invention further relates to an end cap for use with a conductive connecting element, wherein the connecting element comprises a conductive body section with a tip at one end, the conductive body section and the end cap forming a touch-proof connecting element. The end cap comprises: a non-conductive body section with a front end and a coupling end, the coupling end being configured to engage with a tip of the connecting element; and an opening within the coupling end, which is shaped to engage securely with at least one groove contained within the tip of the connecting element.

[0025] It is further provided that the coupling end includes a relief shape to snap into at least one of the at least one groove contained within the tip.

[0026] An optional aspect of the present invention provides that the end cap comprises several alignment projections that snap into at least one of the at least one groove contained within the tip. It is further provided that the end cap comprises at least one passage oriented transversely to the opening to facilitate movement over the tip. An unclaimed aspect provides that the opening is cylindrical throughout. The invention further relates to a charging socket for use within a vehicle according to claim 9, for receiving a connector assembly of a plug-in charging system. The charging socket comprises: a pin-shaped connector configured to engage with a socket connector contained within the connector assembly; and a non-conductive end cap attached to the pin-shaped connector.The end cap has a front end and a coupling end, the front end being closed and the coupling end having an opening shaped to fit over the tip. The coupling end has a relief shape to snap into a groove formed within the tip. An optional aspect of the present invention provides that the end cap includes several alignment projections outside the relief.

[0027] The end cap has at least one opening that is oriented transversely to the opening. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] The present invention is particularly emphasized in the appended claims. However, other features of the present invention become more apparent, and the present invention is best understood with reference to the following detailed description in conjunction with the accompanying drawings, wherein: Fig. 1 represents a vehicle charging system, as considered by a non-limiting aspect of the present invention. Fig. 2 represents a charging socket, as considered by a non-limiting aspect of the present invention. Fig. 3a-3b represent a touch-proof connecting element, as considered by a non-limiting aspect of the present invention. Fig. 4a-4f represent an end cap, as considered by a non-limiting aspect of the present invention. Fig. 5a-5f represent an end cap according to a non-inventive embodiment. Fig. 6a-6f represent an end cap according to a non-inventive embodiment. DETAILED DESCRIPTION

[0029] As required, detailed embodiments of the present invention are disclosed here; however, the disclosed embodiments are, of course, merely exemplary of the invention, which may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of specific components. Therefore, the specific structural and functional details disclosed here should not be interpreted as limiting, but merely as a representative basis for teaching a person skilled in the art to use the present invention in various ways.

[0030] Fig. Figure 1 represents a charging system 10 capable of facilitating the charging of a vehicle charging system 14 with energy supplied from a wall outlet or charging station 16, as considered by a non-limiting aspect of the present invention. The system may include a cable assembly 18 with multiple conductive wires and / or other conductive elements to facilitate the supply of current between the charging station 16 and the vehicle charging system 14. One end of the cable assembly 18 may include a connector assembly 22 configured to be received within a charging socket 24 belonging to the vehicle charging system. The connector assembly 22 may be of the type described in United States Patent No. 7,878,866, the disclosure of which is hereby incorporated in its entirety by the reference.

[0031] The charging socket 24 can be configured to facilitate the establishment of an electrical connection between multiple electrically conductive elements of the vehicle charging system 14 and the charging station 16. The charging socket 24 can facilitate the desired electrical connection by providing a connection between conductive elements and / or by guiding the vehicle charging system and the conductive elements of the wiring harness into an engagement arrangement. The charging socket 24 can be configured to support a connection methodology with multiple connecting pins or terminals for facilitating the electrical connection of the vehicle charging system and the conductive elements of the wiring harness, including, but not limited to, those specified in Society of Automotive Engineers (SAE) J1772 and International Electrotechnical Commission (IEC) 51851.

[0032] Fig. Figure 2 represents the charging socket 24, as considered by a non-limiting aspect of the invention. The charging socket 24 shown can be configured to facilitate the electrical connection of the conductive elements 30 of the vehicle charging system to the conductive connecting elements 32 of the cable set 18 by guiding the elements into engagement with one another. The vehicle charging system 14 is shown having conductive elements 30 terminating an arrangement of touch-proof, pin-shaped connecting elements 34. The touch-proof connecting elements can be connected to five corresponding conductive wires 36 leading to associated features of the vehicle charging system 14 or to other vehicle subsystems. The conductive elements 32 of the cable set are shown configured as five open terminals 38 connected at one end to five conductive wires 40 of the cable set 18.

[0033] The charging socket 24 comprises a drum 42 and a base 44. Each can be made of plastic or non-plastic parts formed in a molding process, such as injection molding. The drum 42 can include multiple through-hole openings 48 shaped to guide the cable harness connectors 38 relative to the corresponding vehicle charging system connectors 34. The base 44 can include an opening 50 for receiving the drum 42. The base 44 can include multiple mounting device openings 54 through which mounting devices can be received to facilitate mounting the charging socket 24 to the vehicle charging system 14 or any other section of the vehicle 12. Optionally, the drum 42 can lack features (e.g., mounting device openings) for direct mounting to the vehicle.The drum 42 can include a locking element 60 which is operable with a latch or other locking feature (not shown) on the cable set 18 to attach the cable set 18 to the charging socket 24 in a removable manner.

[0034] The drum 42 can include a first alignment feature 64 that is to be aligned with a second alignment feature 66 on the base 44. The first and second alignment features 64, 66 can be projections (as shown) or other protrusions and / or visually identifiable features (barcode, target, etc.). The first alignment feature 64 is shown on an outer cylindrical section of the drum 42, and the second alignment feature 66 is shown near the opening 50 in the base 44, which is used to receive the drum 42. The correct alignment of the alignment features 64, 66 can be checked to ensure that the drum 42 is correctly positioned within the base 44 and / or relative to the mounting device openings 54. The ability to maintain tight dimensional tolerances between the drum 42 and the base 44, e.g.,The correct rotational alignment of the alignment features 64, 66 can be helpful in improving wear and tear on the conductive elements 30, 32 when the conductive elements 30, 32 are repeatedly engaged and disengaged from each other.

[0035] Fig. Figures 3a-3b represent a touch-proof connecting element 80, as considered by a non-limiting aspect of the present invention. The connecting element 80 can be configured for use as one of the connecting elements 34 contained within the charging socket 24. The connecting element 80 can comprise an electrically conductive body section 82 and a non-conductive end cap 84. The body section 82 can be made of a conductive material and have a point 86 at one non-recessed end. Optionally, the other end can be recessed to include an opening (not shown) shaped to receive the conductive wires. Fig. 3a shows the connecting element 80 before the end cap 84 is attached to the tip 86. Fig. Figure 3b shows the connecting element 80 after the end cap 84 has been attached to the tip 86. Once the end cap 84 is attached, the connecting element 80 becomes touch-proof in that a person or other device would unlikely accidentally touch the tip 86 of the conductor 82 in a manner that would likely create an electrical connection with one of the conductive wires 36.

[0036] Fig. 4a-4f represent the in Fig. Figures 3a-3b show the end cap 84 in more detail. The end cap 84 can be made of any non-conductive material, such as plastic or rubber, but is not limited to such materials. In addition to the advantage of insulating the tip 86 of the conductive body 82, the non-conductive material composition of the end cap 84 can also be selected to facilitate the insertion of the connecting element 80 into a receiving device, for example, by providing a low-friction surface or a specially shaped surface (e.g., the conductive section 82 is shown as a turned component, so in some configurations it may be more cost-effective to add a special shape to the tip 86 using the end cap 84, rather than engaging it in an expensive turning operation or the like).Although the end cap 84 is described as non-conductive, the present invention naturally also considers the possibility that the end cap 84 is made of a conductive material if it is not desirable to insulate the tip 86, such as if the end cap 84 is used to facilitate insertion operations, where accidental contact with the connecting element is not a problem.

[0037] An outer section 90 of the end cap 84 is shown to widen outwards from a front end 92 to a coupling end 94. Although the outer section 90 may have other shapes, the widening shown is considered advantageous in facilitating insertion into a socket-shaped connection, such as the connections included in the desired connecting element arrangement above. The front end 92 is shown as closed in that it is formed solid from the material that forms the end cap 84. Optionally, a recessed or flattened section 96 may be included in the front end 92 to limit the length of the end cap 84 and / or to provide a rounded surface. The coupling end 94 corresponds to a section of the end cap 84 that engages with or presses against a surface 98 located on the body section 82 (see Fig. 3a-3b). The coupling end 94 can include an opening 100 through which the tip 86 can be inserted. The opening 100 is shown tapered within the coupling end 94 to create a relief 104. The relief 104 can be dimensioned to lie within a corresponding groove 106 within the tip 84, such as a locking contact, but is not limited to creating a snap-fit ​​connection. The snap-fit ​​connection can provide a sufficient amount of force to securely hold the end cap 84 to the tip 86.

[0038] To facilitate the centering of the end cap 84 relative to the tip 86, the opening can include several projections 110, 112, 114, 116, 118, 120 outside the relief 104. The projections 110, 112, 114, 116, 118, 120 can extend inward relative to the opening 100 to create an interference fit with the tip 86. The projections 110, 112, 114, 116, 118, 120 can be equally spaced around the circumference of the opening 100 and dimensioned to facilitate the centering of the end cap 84 without excessively increasing the force required to position the end cap 84 over the tip 86.

[0039] During the insertion process of the end cap 84 over the tip 86, the end cap 84 may bend slightly outwards as the tip moves longitudinally through the opening 100 to position the relief 104 over the groove 106. The end cap 84 may include passages 124, 126 arranged transversely to the opening 100, and / or channels 128, 130 within the coupling end 94 to further facilitate bending of the end cap 84 during the insertion process. Depending on the material composition and wall thickness of the end cap 84, the size and shape of the passages 124, 126 and / or channels 128, 130 can be adjusted to provide sufficient bending during insertion to allow the relief 104 to be securely inserted into the groove 106 without compromising its structural integrity.

[0040] As in Fig. As shown in Figure 3a, the tip 86 can include a tapered edge 132 leading to the groove 106. The tapered edge 132 can be used to facilitate the movement of the relief 104 into the groove 106 in a way that helps to alleviate stresses applied to the end cap 84 while also improving the depth of the groove 106. Instead of having a cylindrical section 134 leading into the tapered edge 132, the tapered edge 132 can optionally be eliminated to provide a flat or smooth insertion surface to the groove 106, for example, if the material composition of the end cap 84 allows a sufficient amount of bending without excessively increasing the insertion force. The thickness of the end cap 84 can also be selected such that, if the relief 104 is correctly positioned within the groove 106, the tapered edge 132 is not easily accessible through one of the transverse openings 124, 126.This can be helpful in limiting the probability that the tip 86 is accidentally touched through one of the transverse openings 124, 126.

[0041] Fig. Figures 5a-5f represent an end cap 150 according to a non-inventive embodiment. The end cap 150 can be configured similarly to the one shown in Fig. The end cap 84 shown in Figures 4a-4f can be made of a non-conductive material that creates a snap-fit ​​connection with the groove 106. Instead of having a tapered opening to create the snap-fit ​​connection, the end cap 150 can include several projections 152, 154, 156, 158. The projections 152, 154, 156, 158 can also be dimensioned and shaped to create a relief 162 on which the groove 106 sits, further facilitating the centering of the end cap 150. The projections 152, 154, 156, 158 can be equally spaced around the circumference of an opening 164 through which the tip 86 extends. Four projections 152, 154, 156, 158 are shown to be included to facilitate the attachment of the end cap 150, but the present invention fully considers the use of more or fewer projections 152, 154, 156, 158.Since the projections 152, 154, 156, 158 do not form a continuous surface completely around the circumference of the opening 164, less surface area of ​​the end cap 150 engages with the tapered edge 132 of the tip 86. This can be helpful in improving insertion forces, especially when size constraints or material properties require a smaller end cap 150 or a larger groove 106. Due to the use of the projections 152, 154, 156, 158, the end cap 150 can optionally be designed without the need for transverse passages.

[0042] Fig.Figures 6a-6f represent an end cap 180 according to a non-inventive embodiment. The end cap 180 can be configured similarly to the end caps 84, 150 described above in that it can be made of a non-conductive material capable of insulating one end of the conductive body section 82. The end cap 180 can comprise a closed front face 182 and an open coupling end 184. The coupling end 184 can include an opening 186 through which the tip 86 extends. The opening 186 is shown to have a uniform width / diameter throughout. The width can be selected to engage with serrations (not shown) formed within the tip 86.The serrations may be similar to the groove 106 shown above and / or they may be formed by providing an undercut on a rear section of the tapered edge 132, so that when the end cap 180 is inserted over the tip 86, the undercut section usually engages or penetrates the end cap 180 to prevent removal. Optionally, several grooves and / or undercuts may be included within the tip to further facilitate retention of the end cap.

[0043] The present invention primarily describes the end caps as generally radially shaped, and the opening(s) / projections contained therein arranged radially around a generally cylindrical opening. However, the present invention considers its use and application entirely with any type of conductive body, so that the end cap need not necessarily have a generally radial shape. The end cap can be shaped and dimensioned differently from the illustrations provided herein to facilitate the insulation of a tip 86 or other section of a conductive body 102 with a non-radial shape. The present disclosure also considers fastening the end cap to the tip 86 of the conductive body section 82 by means other than those associated with inserting the end cap over the tip 86 to create a snap-fit ​​connection, such as...by forming the end cap directly on the conductive body section 82. This overmolding of the end cap can be advantageous when attaching the end cap to a tip 86 without having to specially shape the end cap or the tip 86, e.g. without having to machine a groove inside the tip.

Claims

[1] Touch-proof connecting element (80) comprising: a conductive body section (82) with a tip (86) at one end; and a non-conductive end cap (84) attached to the tip (86), the end cap (84) comprising a front end (92) and a coupling end (94), the coupling end (94) having an opening (100) shaped to fit over the tip (86), the opening (100) of the coupling end (94) having a relief (104) to snap into a groove (106) formed within the tip (86), characterized by , that the end cap (84) has at least one passage (124, 126) which is oriented transversely to the opening (100) to allow the movement of the relief (104) into the groove (106). [2] Connecting element (80) according to claim 1, wherein the end cap (84) comprises several alignment projections (110, 112, 114, 116, 118, 120) outside the relief (104) to facilitate the centering of the coupling end (94) relative to the tip (86). [3] Connecting element (80) according to claim 1, wherein the tip (86) comprises several prongs which are shaped to engage with the opening (100) inside the end cap (84). [4] Connecting element (80) according to claim 1, wherein the other end of the body section (82) has an opening shaped to receive conductive wires. [5] Connecting element (80) according to claim 1, wherein the front end (92) of an outer section (90) of the end cap (84) widens outwards towards the coupling end (94), wherein the coupling end (94) comes into contact with a surface (98) of the body section (82) which is located behind the tip (86). [6] Connecting element (80) according to claim 1, wherein an outer diameter of the coupling end (94) is approximately equal to an outer diameter of the body section (82) near the coupling end (94) in order to provide a flush outer surface at a boundary between the end cap (84) and the body section (82). [7] End cap (84) for use as part of a conductive connecting element (80), wherein the connecting element (80) comprises a conductive body section (82) with a tip (86) at one end, wherein the conductive body section (82) and the end cap (84) form the touch-proof connecting element (80), wherein the end cap (84) comprises: - a non-conducting body section with an anterior end (92) and a coupling end (94), and - an opening (100) within the coupling end (94) which is shaped for secure engagement with at least one groove (106) formed within the tip (86) of the conductive body section (82) of the connecting element (80), whereby the coupling end (94) is configured to engage with the tip (86) of the body section (82); wherein the opening (100) of the coupling end (94) has a relief (104) to snap into at least one of the at least one groove (106) formed within the tip (86); characterized by , that the end cap (84) has at least one passage (124, 126) which is oriented transversely to the opening (100) to facilitate movement over the tip (86). [8] End cap (84) according to claim 7, wherein the end cap (84) comprises several alignment projections (110, 112, 114, 116, 118, 120) which snap into at least one of the at least one groove (106) formed within the tip (86). [9] Charging socket (24) for use in a vehicle to accommodate a connector assembly (22) of a plug-in charging system, the charging socket (24) comprising: a pin-shaped connector (80) shaped to engage with a socket connector contained within the connector assembly (22), the connector (80) comprising a conductive body section (82) with a tip (86) at one end and a non-conductive end cap (84) attached to the pin-shaped connector (80), the end cap (84) comprising a front end (92) and a coupling end (94), the front end (92) being closed and the coupling end (94) having an opening (100) shaped to fit over the tip (86), the opening (100) of the coupling end (94) comprising a relief (104) to engage in a groove (106), which is formed within the tip (86) to snap into place, characterized by, that the end cap (84) includes at least one passage (124, 126) which is oriented transversely to the opening (100). [10] Charging socket (24) according to claim 9, wherein the end cap (84) comprises several alignment projections (110, 112, 114, 116, 118, 120) outside the relief (104).

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