Connector arrangement

Abstract

Connector arrangement, especially for high current applications and / or high voltage applications, comprising the connector arrangement (100): -- a connector (1); -- a mating connector (2) for connecting to the connector (1); wherein the connector (1) has a lamellar cage (3) with a base element (4) and with a plurality of contact lamellae (5), wherein the contact lamellae (5) -- are connected to the base element (4) in a rear section (6), -- project towards the mating connector (2) from the base element (4) and -- have a front section (7) facing the mating connector (2), wherein the mating connector (2) has a one-piece designed contact element (9) with a head section (10) and a contact part (11), wherein the contact part (11) protrudes from the head section (10), wherein the head section (10) has a collar (12) which extends in a radial direction (R) beyond the contacted part (11), wherein the contact element (9) and / or the mating connector (2), in particular in the state connected to the connector (1), is displaceable between a first position (P1) and a second position (P2), in particular along an insertion direction (E), where in the first position (P1) -- the contact element (9) and / or the mating connector (2) can be displaced along the insertion direction (E) with a force of less than 5N, in particular without force. and / or -- a radial play is formed between the contact lamellae (5) and the contacted part (11), wherein in the second position (P2) the collar (12) of the head section (10) mechanically contacts the front section (7) of the contact lamellae (5) such that the contact lamellae (5) are displaced along the radial direction (R) towards the contacted part (11) and thereby electrically contact the contacted part (11) in a contact section (13) of the contacted part (11) and in particular clamp the contacted part (11) between them.

Description

Field of invention

[0001] The invention relates to a connector arrangement. State of the art

[0002] Connector assemblies typically consist of a plug connector and a mating connector that can be mated together. Connectors for high-current applications (e.g., for electrical currents exceeding 10 A, preferably exceeding 50 A or even 100 A), for example, for electric vehicles or automotive applications, often feature contact elements with spring-loaded lamellae, such as toroidal or socket-shaped lamella cages, which are connected to a (e.g., shielded) cable, for example, by mechanical crimping or ultrasonic welding. In other cases, the lamella cages can also be directly attached to a carrier element, such as a printed circuit board, for example, by soldering or press-fit contacting. Such connectors are designed to be mated with a mating connector, which, for example, has a contact element, such as a contact pin or contact blade, or the like.The connector can be mated with the mating connector along a specific insertion or mating direction. In the final state, a contact element of the mating connector (also called a mating contact element) makes electrical contact with the contact element of the connector. The spring lamellae of the connector's contact element should, in the final mated state, exert a normal force (or contact normal force) that ensures an electrical connection to the mating contact element even under mechanical and / or thermal loads and across all manufacturing tolerances.

[0003] This normal force is usually limited, however, because the insertion forces when connecting the connector to the mating connector should not exceed a defined level. To reduce the high insertion forces for the operator, lever or slide mechanisms, for example, can be used, thus reducing the operating force required during mating. However, such lever or slide mechanisms are often complex and expensive, require a large range of motion for operation, and do not prevent damage to the rubbing surfaces as the contact element of the mating connector slides along the contact lamellae. It is possible, however, to reduce the insertion forces and also minimize surface damage during the mating process by applying a friction-reducing coating to at least one contact partner (contact element and / or mating contact element).However, this increases the cost and complexity of the manufacturing process for the corresponding contact partner and does not reliably prevent damage to the surfaces of the contact partners. Furthermore, it can potentially increase the contact resistance in the area of ​​the contact point.

[0004] In other applications, the contact partners (contact element and mating contact element) can be designed, for example, as busbars. These can be screwed together to ensure a permanent connection. With M4 screws, for example, a contact force or normal force in the range of 2000 N to 2500 N can be achieved. Even higher normal forces can be achieved using M5 or M6 screws. However, such a screw connection of the contact partners requires additional installation space for the screws and the means to tighten or loosen them during maintenance.Furthermore, several additional steps are necessary before and / or after the contact partners are joined, which make the assembly process complex: the contact partners must be aligned exactly to each other in order to tighten the screw, the screw must be positioned, a tool for tightening the screw must be placed, the screw must be tightened, and the tool must be removed.

[0005] From DE 10 2018 202 960 A1, a connector for automotive and / or high-current applications is known in which the contact element is designed as a lamellar cage. To reduce the high insertion forces (between the contact element and the mating contact element) that occur during mating, a lever element is provided for the operator, which is actuated during the mating process when connecting the connector and mating connector.

[0006] From DE 10 2017 213 093 A1 a plug connector for high current applications is known, wherein the contact element is designed as a lamellar cage and in which a high insertion force (between contact element and counter-contact element) must be overcome during the insertion of a mating contact element into the contact element.

[0007] From DE 10 2019 131 791 A1 a contact element of a connector is known, wherein the contact element is directly connected to a printed circuit board and wherein the contact element can be contacted by inserting a pin-like contact element of a mating connector.

[0008] From DE 20 2008 005 394 U1 a high-current printed circuit board connector with a lamellar cage is known, wherein the connector can be pressed into a printed circuit board by means of a plug socket and can thus be electrically contacted.

[0009] From WO 2007 / 107 208 A1, a plug connection of the Radsok type (Radsok connector) with a socket of the Radsok type (Radsok socket) and a plug that can be inserted into the socket is known, which in the connected state form a connector arrangement, wherein locking means are formed on the Radsok socket and the plug which enable a defined fixing of the Radsok socket and plug.

[0010] A connector is known from DE 10 2018 220 798 A1. The connector comprises a male terminal, a housing with a housing section that receives the male terminal, and a pressure element arranged in the housing section. A female terminal with a proximal section and a contact segment, which is designed in a cantilever-like shape and extends from the proximal section, is inserted into the housing section. The pressure element holds the contact segment of the female terminal, which is inserted into the housing section between the pressure element and the male terminals, elastically deforms the contact segment, and presses the contact segment against the male terminal.

[0011] From DE 38 83 431 T2, an interlocking electrical contact assembly is known, consisting of a two-forked receiving terminal with a base and two contact arms projecting from the base, wherein the contact arms have contact surfaces with an inwardly facing basic orientation and cam surfaces with an outwardly facing basic orientation, which converge towards each other at larger distances from the base, and a three-forked plug terminal with a base, a central contact bar extending from the base, wherein the central contact bar has a width that is less than or equal to the distance between the contact surfaces of the contact arms, and the three-forked plug terminal further comprises two cam arms extending from the base on opposite sides of the contact bar, wherein the cam arms have cam surfaces with an inwardly facing basic orientation.which converge towards each other with smaller distances to the base, and the cam surfaces of the triple-forked connector are arranged such that they engage with the cam surfaces of the double-forked connector when the plug and receiver are moved sufficiently against each other, and press the contact surfaces of the double-forked receiver into engagement with the central contact bar of the triple-forked connector.

[0012] From US patent 9,748,684 B2, a connector for positioning on a mating connector and establishing an electrically conductive connection is known. The connector comprises a guide and a contact pin. The guide is configured and positioned such that, to establish the electrically conductive connection, contact strips of a contact socket of the mating connector can be guided to the contact pin by means of the guide, the contact strips enclosing the contact pin in a frictional engagement to establish an electrical contact.

[0013] Another connector arrangement is known from JP 5 649 009 B2. Disclosure of the invention

[0014] The invention is based on the understanding that, when a low normal force is present (at the contact point(s) between the contact element and mating contact element) under high temperature fluctuations and / or strong vibration or shaking loads, there is a risk of undesirable relative movements between the contact partners (contact element and mating contact element) and / or contact interruptions. Furthermore, the invention is based on the understanding that a large contact area between the contact partners is advantageous for a long service life of the contact and / or for minimizing heating of the contact point during the transmission of high currents. The invention is also based on the understanding that high insertion forces during a large portion of the insertion path complicate the insertion process of a connector and mating connector.Furthermore, the invention is based on the understanding that the application of normal force between the contact element and mating contact element during the insertion process—i.e., during the path or a large part of the path, e.g., more than 30% of the path, e.g., from a pre-insertion position through an intermediate insertion position (first position) to a final insertion position (second position)—not only complicates and hinders the insertion process, especially when several connectors are simultaneously mated with multiple mating connectors, but can also damage the surfaces of the respective contact partners. For example, if normal force is applied during the insertion process, a contact lamella can leave a scratch or a wear mark on a contacted part.This can undesirably damage or destroy a surface coating and can impair repeated mating and unmating, as such scratches or grooves can cause the contact partner to stick during the mating or unmating process. Furthermore, a high insertion force (between the contact partners) can even undesirably reduce the number of contact partners in a connector, since with a large number of contact partners, the insertion forces, even when using lever or slider designs, can become so high that the operating force is no longer acceptable for the operator. Finally, the invention is based on the understanding that the coating of the contact partners can reduce the current-carrying capacity and increase costs.

[0015] Therefore, there may be a need to provide a connector assembly that enables the connection or mating of a connector with a mating connector (which may also be designed as a knife strip or the like) with the lowest possible insertion force, which simultaneously exhibits a high normal force between the contact partners in the electrically contacted state, which has a high current-carrying capacity, which provides the largest possible contact area between the contact partners, which enables permanent, secure, reliable and uninterrupted electrical contact between connector and mating connector even under thermal cycling and / or mechanical stresses such as vibration or shaking, and which requires only a small installation space for the contacting process.The installation space required allows for safe operation (no risk of touching live parts), where at least the contact partners (contact element and mating contact element) can be manufactured cost-effectively and easily, and where establishing the contact with the desired normal force is possible in a simple manner with as few steps as possible, even in complicated installation space situations.

[0016] Similarly, there may be a need to provide a mating connector with the properties described above. Advantages of the invention

[0017] This need can be met by the subject matter of the present invention according to the independent claims. Advantageous embodiments of the present invention are described in the dependent claims.

[0018] According to a first aspect of the invention, a connector arrangement is proposed, particularly for high current and / or high voltage applications, especially for automotive applications, particularly for electric vehicles (which may include, for example, fully or partially electrically powered aircraft, ships, boats, e-bikes, motorcycles).

[0019] The connector assembly comprises a connector and a mating connector for mating with the connector. The connector has a lamellar cage with a base element and a plurality of contact lamellae. The contact lamellae are connected to the base element at a rear section. The contact lamellae project from the base element towards the mating connector and have a front section facing the mating connector. The mating connector has a contact element with a head section and a contacted part, the contacted part projecting from the head section, the head section having a collar that extends radially beyond the contacted part. The contact element and / or the mating connector is displaceable between a first position and a second position, particularly when the mating connector and connector are mated together.In the first position – and preferably also from a pre-insertion position to the first position – the contact element and / or the mating connector can be displaced along an insertion direction with a force of less than 5 N, in particular without force. Alternatively or additionally, in the first position – and preferably also from a pre-insertion position to the first position – a radial clearance is formed between the contact lamellae and the contacted part of the mating connector. In the second position, the collar of the head section mechanically contacts the front section of the contact lamellae such that the contact lamellae are displaced along the radial direction towards the contacted part, thereby electrically contacting the contacted part in a contact section of the contacted part.

[0020] This advantageously results in the insertion or mating of the connector and mating connector being achieved largely without force or with a very low insertion force, and the actual application of the contact normal force to the contact element of the mating connector only occurs at the end of the insertion process. In contrast to conventional lamellar cages, where the insertion process of the mating connector's contact element must already cause the contact lamellae to expand radially outwards in the area of ​​the contact lamellae (so-called "opening peak" in the insertion force), and where the frictional force between the contact lamellae and the contact element must also be overcome further along the insertion path, according to the invention, an increased force is only required at the end of the insertion or mating process. This increased force is necessary so that the contact lamellae can apply the contact normal force to the contact element.This advantageously simplifies the assembly process, furthermore allows for larger manufacturing tolerances, as tilting due to insertion forces is prevented, and also advantageously enables correction of the connector and mating connector arrangement even during the assembly process. Furthermore, the joining and / or plugging process in a production line can advantageously be distributed across different, spatially separated machines or workstations: in a first step, connectors and mating connectors and / or contact elements and lamellar cages are simply plugged or joined together, for example, until the first position is reached. This occurs essentially without force or with a very low insertion force. In this first position, the contact lamellae and the contacted part advantageously already overlap. In a second step (the, for example,(This can also be done at another workstation or by other machines or technicians) and then the contact normal force can be applied, thus creating the desired electrical (and also mechanical) connection. In this way, pre-assembly is possible. It may also be possible, for example, to secure the pre-assembly process (reaching the first position), e.g., mechanically, for example, by a type of primary locking mechanism, so that the pre-assembled connector assembly can be easily and securely transported to another location.

[0021] Furthermore, this advantageously prevents damage or destruction to the surfaces of the contact element and contact lamellae during the joining process along a longer path (e.g., from the beginning of the overlap between the contact lamella contact point and the contacted part of the contact element to the contact section of the contacted part). This also allows for repeated mating and unmating of the connector and mating connector (e.g., for repairs, maintenance, etc.), thereby advantageously improving the durability of the connector assembly and the associated components.

[0022] Furthermore, it is advantageous to increase the number of contact lamellae compared to conventional connector arrangements and / or to increase the applied normal force on the contact lamellae in the mated position. Alternatively or additionally, a material with a higher spring constant or a higher modulus of elasticity can be used for the contact lamellae. This can advantageously achieve improved current-carrying capacity over the lifetime of the connector, reduce the thermal stress on the contact partners in the contact area (lower contact resistance), and thus increase the robustness of the connector arrangement, e.g., against thermal cycling, vibrations, and / or manufacturing tolerances.Since, according to the invention, an increased axial force is only required at the end of the insertion process (on the (particularly short) path from the first position to the second position) to generate a radially acting contact normal force, an actuating element can be arranged on the connector and / or the mating connector, which, despite a potentially limited operating path, has a particularly high force transmission (e.g., more than 10:1, more than 50:1, or more than 100:1). In cases with limited installation space and little room for the movement of such an actuating element, the proposed invention can make a significant force transmission possible using simple means. Such an actuating element—optionally provided, but not absolutely necessary and therefore not essential—can, for example, be designed as a lever or a slider. Such an actuating element can, for example,It may be arranged on a connector housing or on a mating connector housing. It may, for example, have a cam structure that interacts with a complementary pin or bolt on the mating element (if the actuating element is arranged on the connector or connector housing, then the bolt or pin may be arranged on the mating connector or mating connector housing).

[0023] Furthermore, the mechanical contact of the collar with the front section of the contact lamellae advantageously increases the number of contact points between the contact element and the lamella cage. For example, this can result in at least a doubling of the contact points compared to a situation where only the contacted part is in mechanical and electrical contact with the contact lamellae. This advantageously increases the current-carrying capacity, reduces the electrical contact resistance, increases the redundancy of the contact points, reduces the thermal stress on the contact point(s), and also further improves robustness against (radial) manufacturing tolerances and against (radial) vibrations and / or shaking loads. This is because the contacts between the collar and the front section of the contact lamellae are formed along the axial direction and are therefore orthogonal to the preferably radially acting or...trained contact points between contact lamellae and contacted part.

[0024] The insertion direction can be defined, for example, as the direction along which the mating connector is plugged into the connector. It can preferably be defined, for example, as the direction along which the contact element is moved relative to the lamellar cage to effect contact. The insertion direction can also be referred to, for example, as the axial direction.

[0025] The radial direction runs, for example, perpendicular to the insertion direction. A circumferential direction runs, for example, around the insertion direction.

[0026] The lamellar cage can be designed, for example, so that the contact element, particularly with its contacted part, can be inserted into an interior space of the lamellar cage. The base element of the lamellar cage can also be referred to as a collar or be designed, for example, as a collar to which the contact lamellae are attached. The base element and contact lamellae can be manufactured, for example, as a single piece, e.g., from a single piece of sheet metal. They can, for example, be designed as a stamped and bent part. The contact lamellae can be designed, for example, to make contact with the contacted part, in particular to make electrical contact.

[0027] The contact lamellae can, for example, have a cantilevered or free end in the front section, or be designed to be cantilevered in the front section. It can be provided, for example, that the contact lamellae are not connected to each other in the front section. Such a free end can, for example, point directly towards the mating connector and thus represent a kind of end face of the contact lamella in the direction of the contact element. However, there can also be embodiments in which the contact lamellae are bent at or with their free end and point, for example, radially or even towards the base element. In such a case, a part of the front section forms the end face that projects furthest from the base element in the direction of the contact element.

[0028] It is also possible, in principle, for the contact lamellae in the front section to be connected to each other, e.g. by means of a head element. Such a head element can be designed like the base element, e.g. in the form of a collar.

[0029] The contact part can, for example, project from the head section of the contact element along the insertion direction. The contact part can, for example, be designed as a pin, a prong, or a contact blade; generally, as a male contact part. The contact element can, for example, have a mushroom shape, with the contact part representing the stem and the head section the cap of the mushroom. In longitudinal section, the contact element can, for example, have a T-shape. It can, for example, project at least 2 mm from the head section, preferably at least 5 mm, and particularly preferably at least 10 mm.

[0030] The shift between the first and second positions can occur, for example, along the insertion direction. The first position can be, for example, an intermediate insertion position in which a large portion (e.g., more than 70%, preferably more than 90%) of the insertion path between the contacted part and the contact element has already been traversed. Here, the insertion path can be defined, by way of example, as the path along which the contacted part overlaps the contact element, viewed in the radial direction. The second position can be, for example, an end insertion position.

[0031] In the first position, for example, a gap can form between the contacted part and the contact lamellae (with simultaneous overlap of the contacted part and contact lamellae). This gap can, for example, allow radial play between the contacted part and the contact lamellae.

[0032] In the second position, the contact lamellae can clamp the contacted part between them. This clamping can be formed, for example, along the radial direction. "Clamping" here means that the contacted part—assuming the collar remains unchanged on the front section in the second position—is held securely between or by the contact lamellae. Thus, viewed along the radial direction, the contacted part is clamped or held firmly between the contact lamellae. In other words, in the second position, the contacted part has an excess of space relative to the contact lamellae (with only two contact lamellae positioned approximately opposite each other, this excess could, for example, be in the distance between the contact lamellae).

[0033] For example, the contact lamellae may enclose a contacting space. The contact lamellae may simply be arranged around the contacting space, for instance, along the direction of rotation. The contacted part may be located in the contacting space with its contact section within the contacting space and be contacted there (within the contacting space) by the contact lamellae.

[0034] In other words, the contact space can, for example, be located radially inside between the contact lamellae. It can, for example, be part of the interior of the lamella cage. The contacted part of the contact element can, for example, be inserted into the contact space in the first position and in the second position. The contact space can, for example, have an interference (especially along the radial direction) with respect to the contacted part when not fully assembled (i.e., during the insertion or joining process up to the first position). When fully assembled, especially in the second position, the contacted part can, for example, have an interference (especially along the radial direction) with respect to the contact space.

[0035] The term "force-free" is to be understood as meaning that the joining or mating of connectors and mating connectors requires only a negligible force, at least up to the first position, and in particular, no opening peak for pushing apart contact lamellae or frictional force between the contact partners needs to be overcome. Especially for power contacts in high-current or high-voltage applications, a joining or mating force of less than 10 N, preferably less than 5 N, and most preferably less than 3 N, can be considered "force-free".

[0036] The contact lamellae can, for example, be designed to be elastically reversible. This means that when the contact element returns from the second position to the first position, the contact lamellae move back to their original position (i.e., they move radially away from the contacted part). This advantageously allows for unplugging without significant force and / or without damaging the surfaces of the contacting partners. Furthermore, it enables a subsequent plugging or joining process, at least up to the first position, to be (almost) force-free or with play between the contact lamellae and the contacted part.

[0037] Particularly in the case of contact lamellae arranged opposite each other, it can be provided, for example, that the collar mechanically contacts the contact lamellae in their front section in such a way that the contact lamellae are displaced radially inwards as the contact element moves from the first position to the second position, thereby electrically contacting the contacted part in the contact section. In the second position, the contact lamellae are then displaced radially inwards and contact the contacted part in the contact section.

[0038] During the movement from the first position to the second position, and in the second position itself, the collar can, for example, be in axial contact with the front section of the contact lamellae, thereby exerting an axial force on the contact lamellae. This force leads to at least partial displacement of the contact lamellae in a radial direction towards the contacted part. In the second position, the collar can be pressed against the front section of the contact lamellae, particularly along the axial direction.

[0039] According to the invention, the contact element is designed as a single piece. For example, the contacted part and the head section can be designed to be permanently separable from one another. It can be provided, for example, that the head section and the contacted part are rigidly connected to each other, and in particular, not movable relative to each other. Alternatively, it can be provided that the contacted part is movable relative to the head section, for example, along the axis of the contacted part. For example, the contacted part can be movable through an opening in the head section. The contacted part and the head section can be made, for example, of an electrically conductive material, or, for example, of the same material. In an alternative embodiment, the head section and / or the collar can be made, for example, of a different material than the contacted part.made of an insulating material, wherein the head section and / or the collar is designed or configured or serves only to apply the axial force to the front section of the contact lamellae during displacement from the first position to the second position.

[0040] The contact element can be designed, for example, as a pin, a contact blade, or the like. It can, for example, be generally designed as a male contact element that can be inserted into the lamellar cage as a female contact element.

[0041] The contact part can, for example, have a diameter in the range between 2mm and 30mm, preferably between 4mm and 20mm.

[0042] A single lamella or contact lamella can, for example, have a thickness in the range of 200 µm (200 micrometers) to 3 mm, preferably between 400 µm and 2 mm. The width of a contact lamella can, for example, be greater than its thickness.

[0043] It may be provided, for example, that the diameter of the lamellar cage is at least 20 µm larger than the diameter of the contacted part, preferably at least 50 µm. The term "comprise" is used synonymously with the term "have" unless otherwise stated.

[0044] In a further development, it is provided that in the second position, the contact lamellae contact the contact section with a radial contact normal force of at least 1 N, preferably at least 5 N. For example, the contact normal force of the contact lamellae, in particular of each contact lamella or the plurality of contact lamellae, is in a range between 5 N and 50 N or even between 5 N and 200 N. This advantageously results in a particularly secure and reliable contact that exhibits low contact resistance over its service life, even under vibration, thermal cycling, or other operating conditions.

[0045] This allows heating at the interface between the contact partners to be advantageously minimized, even at high currents of, for example, more than 50 A or even more than 100 A. Furthermore, this allows for a reduction in installation space, weight, and material usage in the contact zone, particularly at the lamellar cage, since reliable contact via high contact normal force enables a smaller number of contact points. This also advantageously increases the service life of the connector assembly.

[0046] In a further development, it is provided that the base element of the lamellar cage is designed to be completely closed. This advantageously results in a particularly stable lamellar cage and prevents the contact lamellae from spreading the base element apart in the second position. This, in turn, advantageously ensures a particularly reliable and lasting application of the contact normal force.

[0047] For example, it may be provided that the base element or the collar or the collar area of ​​the lamellar cage is designed to be ring-shaped and closed.

[0048] The base area can, for example, have a circular or elliptical cross-section in its unloaded state (i.e., before the mating connector is mounted). However, a polygonal cross-section of the base element is also conceivable, e.g., triangular, square, pentagonal, hexagonal, heptagonal, or octagonal. Even more than eight sides are possible.

[0049] The completely closed shape can be achieved, for example, by rolling up an originally flat stamped or bent part, such as one made from a sheet of metal. To keep the base closed, a material-bonded connection (e.g., through welding, bonding, or soldering) can be used. Alternatively, a form-fit connection can be used. For example, at one end of the base, at least one type of eyelet or recess with a neck (flat or narrow neck) can be formed, and at the other end, at least one type of pin with a shape complementary to the eyelet or recess (tongue-and-groove principle). After the stamped or bent part is rolled up, the pin can then be inserted into the complementary eyelet or recess, preventing the base element from unrolling.A positive-locking connection offers the advantage of a particularly simple and cost-effective assembly and temperature-stable connection.

[0050] In a further development, it is provided that the first and second positions are separated by a maximum of 5 mm, preferably a maximum of 2 mm, and most preferably a maximum of 1 mm along the insertion direction. This advantageously ensures that the contact partners (contact lamellae and contacted part) can only rub against each other along a very short, particularly axial, path, thus preventing damage to the surfaces or limiting it to a very small path. Furthermore, this advantageously allows for a connector arrangement that requires only extremely little installation space along the insertion direction. Finally, this method advantageously enables the application of a particularly high normal force, for example, if an actuating element is provided to reduce the operating force.For example, if the distance between the first and second positions is 1 mm and the travel of an optional actuating element, such as a slide or a rotatably mounted lever, is 100 mm, then a force transmission of 100:1 can be achieved. The entire travel of the actuating element, and thus the entire force transmission, can then be used to apply the contact normal force. It is not necessary to waste part of the actuating travel on part of the joining path. Furthermore, it is advantageous for the force transmission to be very uniform along the actuating path, for example, by means of an essentially linear cam profile with a uniform slope in the actuating element. This is because an optional actuating element only needs to be used for the travel distance from the first position to the second position, and not for the entire joining path.Alternatively, with the same force transmission, the actuation path can be reduced, thereby saving installation space or free space for actuating the actuating element.

[0051] In a further development, it is provided that in the first position, the radial clearance between the contact lamellae and the contacted part lies within a range of 5 µm (5 micrometers) to 200 µm (200 micrometers) or within a range of 20 µm to 100 µm. This advantageously allows a high normal contact force to be generated even with a short distance between the first and second positions. Furthermore, a high force transmission can be achieved advantageously, since only a very small radial path needs to be traveled for contacting, or only a very small gap needs to be closed. For example, if an axial path of 1 mm is available between the first and second positions and the gap or radial clearance is a uniform 100 µm all around, a force transmission of 10:1 is already achievable. At the same time, such a small radial clearance also advantageously facilitates the insertion process.The joining process is virtually force-free, at least up to the first position. Such minimal play also allows for a particularly compact design of the lamellar cage and / or the connector in the radial direction.

[0052] In a further development, it is provided that the contact lamellae extend at least partially obliquely from the base element towards the contacted part, or run obliquely towards the contacted part or contact element, or project obliquely from the base element towards the contact element. This advantageously results in the contact lamellae being positioned closer to the contacted part in the first position, thus reducing the radial play or gap compared to when the contact lamellae run straight upwards (i.e., parallel to the insertion direction) or obliquely radially away from the contacted part. Furthermore, this allows the base element to be positioned radially further away from the contacted part, which advantageously enables the contacted part to pass through the base element in the assembled state without colliding with it (thus allowing for a greater insertion depth). The contacted part can, for example, be inserted into a guide element (e.g.,an opening with only a slightly larger diameter) and / or a locking element (viewed along the insertion direction) can be inserted below the base element, thereby better defining and stabilizing the orientation of the contacted part. Furthermore, this makes the radial displacement of the contact lamellae onto the contacted part easier and more reliable, since the contact lamellae already exhibit a preferred radial direction towards the contacting element when no force is applied. This advantageously minimizes the risk of spontaneous or unintentional radial breakage away from the contacted part when an axial force is applied to the front section. It is understood that such radial breakage away from the contacted part can also be prevented by other design measures, such as an outer sleeve or radially arranged support elements, or targeted material treatment (e.g.,thermally or mechanically) before the formation of the lamellar cage. However, an inclined orientation of the contact lamellae represents a particularly simple and cost-effective concept to prevent breakout radially away from the contacting element.

[0053] If the lamellar cage encloses a contacting space inside, into which the contact element or its contacted part is inserted, it may be provided that the contact lamellae extend from the base element at least sectionally obliquely radially inwards, or project obliquely radially inwards, or run obliquely radially inwards.

[0054] In a further development, it is provided that the connector has a contact chamber with an outer wall, wherein the lamellar cage is arranged in the contact chamber, and the base element is arranged inside the contact chamber adjacent to the outer wall.

[0055] This design advantageously makes the lamellar cage particularly easy and reliable to mount in or on the connector. It can, for example, be inserted or slid into the contact chamber. This automatically positions it correctly within the connector. Furthermore, this design allows for a particularly large electrical contact area between the lamellar cage and the connector, thus reducing contact resistance. For example, the contact chamber can be electrically conductive and, at least in the second position, electrically contacted with the base element, for example, from the outside of the base element to the inside of the outer wall of the contact chamber. This also eliminates the need for complex press-fit assembly, for example, into a printed circuit board, or for soldering or welding the lamellar cage to a substrate or electrical component.

[0056] For example, it can be provided that the outer wall of the contact chamber rests against the base element when the lamellar cage is in a force-free state, or is separated from the base element only by a small (radial) gap, e.g., a gap of no more than 500 µm, preferably no more than 200 µm, and particularly preferably no more than 100 µm. In this way, the lamellar cage can still be easily inserted into the contact chamber, ideally without force, while at the same time being positioned very precisely with respect to the radial direction, which ensures a simple and reliable joining process with the mating connector.

[0057] In a further development, it is provided that the base element is supported against the outer wall of the contact chamber in the second position. This advantageously prevents the axial force exerted by the collar on the front section of the contact lamellae from causing the base element to spread apart (excessively) and / or the contact lamellae from shifting axially instead of radially (during the transition from the first to the second position). This also allows for a reduced material thickness of the base element or the use of a material with a lower modulus of elasticity, which can result in cost savings.

[0058] Furthermore, this improves the electrical contact between the base element and the contact chamber in the second position, since the base element forms a secure mechanical and electrical contact with the contact chamber by being supported on the outer wall.

[0059] The support can be provided, for example, in the radial direction.

[0060] For example, a radial movement of the base element (e.g. when the contact element is moved from the first position to the second position) through the outer wall of the contact chamber can be limited to less than 500µm, preferably to less than 200µm and particularly preferably to less than 100µm.

[0061] In a further development, it is provided that a groove is incorporated into the collar of the contact element on the side that assigns to the lamellar cage (a bottom side of the collar).

[0062] This advantageously allows the contact lamellae to be received in the groove, for example, with their front part or the part of the contact lamella that projects furthest from the base element towards the contact element (with its end face). This capture of the front section can, for example, already occur in the first position of the contact element. This, in turn, advantageously ensures that when the contact element is moved (further) from the first position to the second position, the front sections of the contact lamellae are always in a defined position, and the radial contacting process of the contact lamellae against the contacted part is particularly defined and reliable. At the same time, tilting or misalignment of the head or collar during movement from the first position to the second position is prevented, which could, for example, be caused without the groove by individual contact lamellae whose front section, for example,Due to manufacturing tolerances, etc., it could be radially misaligned. The groove thus captures the front sections and then, when moving into the second position, enables the correct establishment of the plug connection in the contact section.

[0063] Furthermore, such a groove can advantageously increase the additional contact area between the contact lamellae and the contact element. By moving the contact element to the second position, the portion of the front section trapped in the groove can ultimately only expand radially, as the axial space available to the contact lamella is reduced. This expansion within the groove leads to a greater filling of the groove with parts or material of the contact lamella, and thus to a larger contact area (the groove has an inner wall, a bottom, and an outer wall). Furthermore, the increased filling of the groove with contact lamella material also increases the force exerted by the contact lamella on the groove walls and bottom, thereby increasing the normal contact force of the contact lamella against the groove's boundary surfaces (the groove walls and bottom).This advantageously creates additional contact paths in the groove, which increases the redundancy of the contact points, reduces the contact resistance and advantageously increases the reliability and service life of the connector arrangement and especially the contact point.

[0064] The groove can be located, for example, between the contacted part and an edge of the collar. It can be circumferential. It can, for example, encircle the contacted part in the direction of rotation. It can, for example, be closed, in particular completely closed. It can, for example, have the same cross-section everywhere.

[0065] For example, it can be designed so that the inner wall of the groove is flush with the outer wall of the contact part. This advantageously traps the contact lamellae particularly close (in the radial direction) to the contact part.

[0066] In a further training course, it is stipulated that the groove runs diagonally outwards on the outer wall of the groove facing the edge.

[0067] This advantageously prevents the contact lamellae from being displaced radially solely due to an axial force applied by the contact element to the front section. Instead, the inclined surface creates a kind of cam-like guide, allowing the contact lamella to be moved or displaced in a controlled radial direction towards the contacted part. This enables more precise control of the displacement. Furthermore, the shape of the inclined surface can advantageously form a displacement-force curve, allowing the translation of the axial displacement of the contact element into a radial displacement of the contact lamellae to be adjusted when the contact element is moved from the first position to the second position. By adjusting the inclined surface, the application of the normal force can be advantageously adapted to the specific installation space and the available travel distance from the first position to the second position.

[0068] The groove can run at an angle on the outer wall of the groove in such a way that a kind of half-funnel shape is visible when looking into the groove.

[0069] For example, the first angle of the groove's outer wall with respect to the insertion direction can lie in a range between 2° and 45° or in a range between 3° and 15°.

[0070] In a further development, it is provided that in the second position, the contact lamellae are arranged with their front sections in the groove. This advantageously increases the contact area between the contact lamellae and the contact element. This is because the contact lamellae are then not only in radial contact with the contacted part, but also contact the head cut, particularly in a very defined manner at a very defined location, namely in the groove. This advantageously increases the number of contact points between the lamella cage and the contact element, reduces the contact resistance, and improves robustness against vibrations, thermal loads, and manufacturing tolerances.

[0071] For example, the contact lamellae can be designed to contact the groove on at least two sides. This advantageously increases the contact area and / or contact points. This enhances robustness against adverse operating conditions and reduces contact resistance. As described above, the groove has three surfaces or sides: an inner wall or groove side (facing the contacted part), an outer wall or groove side (facing the edge of the head section), and a groove bottom or side. The groove bottom can, for example, extend transversely to the insertion direction.

[0072] For example, it can be provided that the surfaces or sides of the groove contacted by the front section are rotated relative to each other by at least 30°. Thus, in the second position, for example, the groove bottom and the inner wall of the groove can be contacted by the front section of the contact lamella, or the groove bottom and the outer wall of the groove, or all three walls can be contacted by the front section.

[0073] In a further development, it is stipulated that the contact lamellae in the front section are bent radially away from the contacted part.

[0074] This advantageously provides a kind of insertion funnel for the contact element, simplifying the joining process of the contact element into the lamellar cage and enabling the joining process even with manufacturing tolerances without damaging the front section. At the same time, this also simplifies the radial displacement of the contact lamellae during the transition from the first to the second position, since the collar can mechanically contact a defined bearing surface.

[0075] For example, the bend can be designed to form a second angle of at least 30°, preferably at least 60°, and particularly preferably at least 110°, relative to the insertion direction. Even a bend of more than 180° is conceivable. In this case, the free end can again point towards the contact lamellae.

[0076] The contact lamellae may be bent radially outwards at the front section or at the free end. They may, for example, be bent outwards beyond the cross-section of the base element or away from the contacted part.

[0077] Another aspect is the proposal for a mating connector, especially for high-current and / or high-voltage applications.

[0078] The mating connector is suitable or configured for mating with a connector having a lamellar cage with a plurality of contact lamellae. The mating connector has a contact element with a head section and a contacted part, wherein the contacted part projects from the head section, in particular along the insertion direction, wherein the head section has a collar that projects radially beyond the contacted part, wherein the contact element and / or the mating connector, in particular in the mated state or in a mated state of connector and mating connector, is displaceable between a first position and a second position, in particular along an insertion direction.In the first position, the contact element and / or the mating connector can be displaced along the insertion direction, particularly with a force of less than 5 N, or even without force. Alternatively or additionally, in the first position, a radial clearance is provided between the contact lamellae and the contacted part of the mating connector. The collar of the head section is configured to mechanically contact a front section of the contact lamellae in the second position such that the contact lamellae are displaced radially towards the contacted part, thereby electrically contacting the contacted part in a contact section of the contacted part and, in particular, clamping the contacted part between them. In other words, the collar is configured to exert axial pressure or force on a front section of the contact lamellae in the second position. Drawings

[0079] Further features and advantages of the present invention will become apparent to the person skilled in the art from the following description of exemplary embodiments, which, however, are not to be interpreted as limiting the invention, with reference to the accompanying drawings.

[0080] They show Fig. 1: A schematic perspective view of a connector arrangement in a non-contacted state; Fig. 2a to 2c: perspective schematic views of two different lamellar cages of a connector ( Fig. 2a and Fig. 2b) as well as a top view of a stamped sheet ( Fig. 2c) as the initial state for a lamellar cage; Fig. 3a and Fig. 3b: Schematic cross-sections through a connector arrangement with the mating connector in a first position ( Fig. 3a) or in a second position ( Fig. 3b); Fig. 4a and Fig. 4b: schematic cross-sections through two further connector arrangements with the mating connector in the second position; Fig. 5a and Fig. 5b: Schematic cross-sections through another connector arrangement with the mating connector in the first position ( Fig. 5a) or in the second position ( Fig. 5b).

[0081] Fig. Figure 1 shows a schematic perspective view of a connector arrangement 100 in a non-contacted state, e.g., in a pre-plugged position. For the sake of clarity, neither an actuating element (such as a lever or a slider) for reducing the operating force during plugging, nor a connector housing, nor a mating connector housing are shown here. Such elements are known from the prior art and do not constitute essential elements for the feasibility of the invention.

[0082] The connector arrangement 100 is here merely an example for high-current applications (e.g. for the transmission of at least 10A, preferably at least 50A and particularly preferably at least 100A) and / or high-voltage applications (e.g. for at least 100V, preferably at least 200V and particularly preferably at least 500V).

[0083] The connector assembly 100 comprises a connector 1 and a mating connector 2 for mating, shown here by way of example along an insertion direction E, with the connector 1, wherein a radial direction R extends perpendicular to the insertion direction E and wherein a circumferential direction U circumferentially surrounds the insertion direction E. The insertion direction E can also be referred to as the axial direction. The connector 1 has a lamellar cage 3 with a base element 4 and with a plurality of contact lamellae 5. The contact lamellae 5 are connected to the base element 4 in a rear section 6. They project from the base element 4 in the direction of the mating connector 2 and have a front section 7 facing the mating connector 2, which here by way of example has a cantilevered end 8.

[0084] The lamellae or contact lamellae 5 of the lamella cage 3 are initially bent radially inwards from the base element 4, or they run obliquely towards the contacted part 11, tilted, bent, or shifted upwards (towards the free end 8). In the front section 7, the contact lamellae 5 are then bent away from the contacted part 11 in a radial direction R, whereby, for example, the free end 8 of the contact lamellae 5 forms an end face 33 facing the mating connector 2. The bending of the front section 7 provides, for example, an insertion funnel, whereby the contact lamellae 5 form an angle between 10° and 35° with respect to the axial direction at the end face 33.

[0085] The connector 1, by way of example, further comprises a contact chamber 14 with an outer wall 15, wherein the lamellar cage 3 is arranged in the contact chamber 14, and the base element 4 is arranged inside the contact chamber 14 adjacent to the outer wall 15. The contact chamber 14 can, for example, be electrically conductive. The contact chamber 14 is arranged on, at, or in a first component 50.

[0086] The lamellar cage 3 can, for example, be electrically connected to the first component 50 via its base element 4. Depending on the embodiment, it can also be mechanically connected to the first component 50, for example by a press-fit connection and / or a soldered connection or the like.

[0087] The first component 50 can be configured, for example, as a printed circuit board 51 or as a power busbar. It can also be directly connected to an electrical power component, such as an inverter, an AC / DC converter, a battery, an electric motor, or the like, or be configured as such a power component. Thus, a particularly simple embodiment of a connector 1 is shown here. It is understood that in other embodiments, the connector 1 can also have a connector housing in which the lamellar cage 3 is arranged.

[0088] The mating connector 2 has a contact element 9 with a head section 10 and a contact part 11. The contact part 11 projects from the head section 10, shown here by way of example along the insertion direction E. The head section 10 has a collar 12 that projects radially R beyond the contact part 11.

[0089] The contact element 9 is shown here as an example electrically connected to a second component 60, e.g. directly as shown here, or via a conductor or a busbar, etc. The second component 60 can be, for example, another power component, e.g., an inverter, an electric machine, a battery, etc. However, the second component 60 can also be a circuit board or a conductor connected to the other power component.

[0090] The contact element 9 and, by way of example, also the mating connector 2, are, especially when connected to the connector 1, movable between a first position P1 and a second position P2 (see e.g. Fig. 3a, Fig. 3b, Fig. 5a, Fig. 5b), in particular along the insertion direction E. The first position P1 can be described, for example, as the pre-contact position or intermediate insertion position – here, the contacted part 11 can, for example, already overlap with the contact lamellae 5, for example, along at least 50% or at least 70% of its longitudinal extent. The second position P2 can, for example, be described as the final contact position or final insertion position, in which the electrical connection is formed in its intended state. A position as described in Fig. Figure 1 can be described as a pre-insertion position, in which, for example, the actual insertion process has not yet led to an overlap of contact lamellae 5 and contacted part 11, or the contacted part 11 only overlaps the contact lamellae 5 to a very small extent (e.g. <20% or <10%) at its front end.

[0091] The first position is P1 (see e.g. Fig. 3a and Fig. 5a) The contact element 9 and / or the mating connector 2 can be displaced along the insertion direction E with a force of less than 5 N, in particular without force. Alternatively or additionally, in the first position P1, a radial clearance is formed between the contact lamellae 5 and the contacted part 11 of the mating connector 2, e.g. in the form of a gap 29 (see e.g. Fig. 3a and Fig. 5a).

[0092] In the second position P2 (see e.g. Fig. 3b, Fig. 4a, Fig. 4b, Fig. 5b) the collar 12 of the head section 10 mechanically contacts the front section 7 of the contact lamellae 5 in such a way that the contact lamellae 5 are displaced along the radial direction R towards the contacted part 11 and thereby electrically contact the contacted part 11 in a contact section 13 of the contacted part 11 and in particular clamp the contacted part 11 between themselves (especially viewed along the radial direction R).

[0093] The second position P2 can be reached from the first position P1, for example, by applying an axial force to the contact element 9, particularly along the insertion direction E. The contact lamellae 5 are mechanically contacted by this axial force or the axial pressure of the contact element 9, the head 10, or the collar 12 (at their front end 7 or their end face) and, under this force, deflect at least partially in the radial direction R towards the contacted part 11. This presses the contact lamellae 5 against the contacted part 11 in the contact section 13. The lamella cage 3 is compressed.

[0094] The lamellar cage 3 can be made, for example, of a highly electrically conductive material such as copper or a copper alloy. The contact lamellae 5 can be designed to be elastically reversible with respect to the displacement of the contact element 9 from the first position P1 to the second position P2. This means that when the contact element 9 is moved back from the second position P2 to the first position P1, or even further, the contact lamellae are moved (approximately) back to their initial position, which they occupied in the force-free initial state. Subsequently, another insertion process can take place, which, in the second position P2 of the contact element, again leads to a radial displacement of the contact lamellae 5 towards the contacted part 11 and to electrical contact with it.

[0095] The insertion direction E can also be defined as the direction given by the displacement direction of the contact element 9 when contacting the lamellar cage 3.

[0096] In the Fig. 2a and Fig. Figure 2b shows perspective schematic views of two different lamellar cages 3 of a connector 1.

[0097] Fig. Figure 2a shows a lamellar cage 3 in which the contact lamellae 5 extend diagonally inwards upwards from the base element 4 (inclined radially towards the contact part 11 which is not shown here).

[0098] In other words, the contact lamellae 5 extend from the base element 4 at least partially diagonally towards the (not shown here) contacted part 11.

[0099] The free ends 8 of the contact lamellae 5 are bent here as an example such that a hook or eyelet is formed. The front section 7 forms the end face 33 of the contact lamellae 5, which faces the contact element 9 and its collar 12 of the mating connector 2. On this end face 33, the collar 12 of the contact element 9 contacts the respective contact lamella 5 and exerts the axial force during the movement from the first position P1 to the second position P2. The free end 8 is bent at an angle relative to the contact section 13, which can be, for example, in a range between 150° and 230° and here is approximately 180° with respect to the insertion direction E. A lamella cage 3 shaped in this way has a particularly smooth end face 33, especially without pointed ends. The end face 33 thus also has a relatively large contact area, compared to a free end 8 forming the end face 33.This minimizes the risk of the end face 33 digging into the collar 12 when axial force is applied to the contact element 9, which could make it difficult to disconnect connector 1 and mating connector 2. Furthermore, such a shaped front section 7 with a strongly bent free end 8 can advantageously form a groove 16 (see . Fig. 4a and Fig. 4b) fill the head section 10 particularly well and advantageously increase the contact area from the contact lamella 5 to the contact element 9. Finally, a [context missing] as in Fig. 2a The bent free end 8 advantageously simplifies the transport and assembly of the lamellar cage 3. This minimizes the risk of different lamellar cages 3, which are used, for example, as bulk material, becoming entangled with each other or of their free ends being damaged during transport, e.g., plastically bent. The end face 33 designed in this way can also function as an insertion funnel, which allows the contacting part 11 to be inserted into the interior of the lamellar cage 3 particularly easily and without entanglement (into a contacting chamber of the lamellar cage 3).

[0100] Fig. Figure 2b shows a lamellar cage 3 in which the free ends 8 of the contact lamellae 5 initially run obliquely radially inwards or obliquely towards the contacted part 11 (not shown here) and are then bent radially outwards (away from the contacted part 11) as in the lamellar cage 3 in Fig. 1. The free ends 8, or a section or part of their sides facing the contacted part 11 (not shown), form the end face 33 as an example. The in Fig. The lamellar cage 3 shown in Figure 2b is particularly easy to manufacture. The slightly radially outward bent shape at the free end 8 advantageously prevents the free ends 8 from digging into the collar 12 when axial force is applied to the contact element 9. A sliding surface is provided that easily converts the axial force into a radial movement of the contact lamellae 5 towards the contacted part 11 (here: radially inwards).

[0101] In the two exemplary embodiments of the Fig. 2a and Fig. 2b shows – merely as an example – the base element 4 of the lamellar cage 3 as being completely closed. Here, it is formed in an exemplary ring-shaped configuration. The lamellar cages 3 thus formed enclose an interior space 34, which can also be referred to as the contacting space. The contacting part 11 of the contact element 9 can be inserted into this interior space 34. The contacting process (between the contacting part 11 and the contact lamellae 5) takes place within it.

[0102] Fig. Figure 2c shows a top view of a stamped sheet as the starting state for a lamellar cage 3, as used, for example, in the Fig. 2a or Fig. Figure 2b is shown. This is therefore ultimately a two-dimensional preliminary stage of the lamellar cage 3.

[0103] In Fig. 2c shows the base element 4 on the lower side and the majority of the contact lamellae 5 projecting upwards from it. At the in Fig. On the left side of the base element 4 (2c), two round tenons 25 can be seen, shown here as an example. These are connected to the base element 4 by means of a neck area with a smaller diameter. At the Fig. On the right side of the base element 4, two recesses 24 (also with a neck area) complementary to the pins 25 are visible. To form the lamellar cage 3, this two-dimensional die can first be pressed or embossed, for example, to create the desired orientation of the contact lamellae 5 (e.g., a section initially angled radially inwards towards the contacted part 11, followed by a radially outwards front section 7 with a more or less strongly bent free end 8). The lamellar cage 3 can then be formed by a winding process, whereby the pins 25 are engaged or inserted into the recesses 24, and the lamellar cage 3 is held dimensionally stable by means of the positive-locking connection of the base element 4 to itself. In other embodiments, the base element can be joined by a material bond (e.g., soldered, welded, glued, etc.).In other embodiments, the base element can simply be wound and / or embossed, for example, so that it automatically retains the predetermined shape, e.g., a closed ring shape.

[0104] The Fig. 3a and Fig. Figure 3b shows schematic cross-sections through a connector arrangement 100 with the mating connector 2 in the first position P1 ( Fig. 3a) or in the second position P2 ( Fig. 3b). A contact lamella 5 can be seen to the left and right of the contacted part 11. Furthermore, it can be seen schematically how the first component 50 is electrically connected to the connector 1 and the second component 60 is electrically connected to the mating connector 2. Also in the Fig. 3a and Fig. For the sake of clarity, no actuating element for reducing the insertion force is shown in 3b, even though such an actuating element (e.g. a lever element, a slide element or the like) may be provided as an option.

[0105] The collar 12 of the contact element 9 has a substantially planar or flat or smooth surface on its underside 35 facing the contact lamellae 5. In other embodiments, a groove 16 can be provided in the collar 12 (see e.g. Fig. 4a and Fig. 4b) may be provided. The groove 16 may have a substantially vertical outer groove wall 20 ( Fig. 4a) or the groove 16 can have a groove outer wall 20 that runs obliquely outwards to the edge 17 of the collar 12 ( Fig. 4b) and, for example, has a first angle W1 with respect to the insertion direction E that is not zero ( Fig. 4b). Furthermore, it is also conceivable, for example, that the underside 35 of the collar 12 is concavely curved, i.e., that it lies lower at the edge 17 than in the area of ​​the contacted part 11. In such a case, it can, for example, form a continuous surface without discontinuities (such as a groove 16).

[0106] Fig. Figure 3a shows the first position P1 when connector 1 and mating connector 2 are plugged together. The contact part 11 already overlaps the lamellar cage 3 to a very large extent (almost 100%) (overlap along the insertion direction E). The collar 12 of the contact element 9 rests loosely against the end face 33, in this case, the front section 7. No or only a slight axial force (e.g., only gravity) is exerted by the contact element 9 on the contact lamellae 5. It is also conceivable that in the first position P1, the collar 12 is still somewhat spaced (e.g., between 1 µm and 500 µm, preferably between 1 µm and 200 µm) from the end face 33 of the contact lamellae 5, so that no force is exerted in the axial direction.

[0107] The connector 1 has a contact chamber 14 with an outer wall 15, wherein the lamellar cage 3 is arranged in the contact chamber 14, wherein the base element 4 is arranged inside the contact chamber 14 adjacent to the outer wall 15.

[0108] The contact chamber 14 also has a base 26 as an example. A recess 27 is arranged in the base 26 of the contact chamber 14, into which, as an example, a front end 31 of the contacting part 11 (here: a cantilevered end of the contacting part 11) can be inserted (e.g., in the second position P2, see Figure 1). Fig. 3b). In this way, for example, the correct radial positioning of the contact part 11 in the second position P2 can be ensured, or the positioning tolerances during assembly can be reduced.

[0109] In Fig. Figure 3a further shows that in the first position P1, the mating connector 2 can be displaced along the insertion direction E with a force of less than 5 N, in particular without force. This is achieved here by means of a radial clearance between the contact lamellae 5 and the contacted part 11 of the mating connector 2 in the first position P1, here in the form of a gap 29.

[0110] Force-free displacement, or displacement with a force of less than 5 N, refers in particular to forces necessary to overcome frictional forces, lifting forces, etc. Overcoming gravity, e.g., during overhead mounting, is not considered here.

[0111] In the first position P1, the radial clearance between the contact plates 5 and the contacted part 11 is, for example, in a range between 5 µm and 200 µm or in a range between 20 µm and 100 µm, e.g., at 20 µm, 30 µm, 40 µm, 50 µm, 60 µm, 70 µm, 80 µm, 90 µm, 100 µm, 130 µm, 160 µm, or 200 µm. In other words, the gap 29 causes the radial clearance and establishes a first distance D1 (in the radial direction R) in the range described above (e.g., between 5 µm and 200 µm, etc.).

[0112] It is clearly evident that in this exemplary embodiment, the contact lamellae 5 in the front section 6 are bent radially away from the contacted part 11 in the direction R. Here, they are bent relative to the insertion direction E by a second angle W2, which is, for example, somewhat greater than 180° and can only be in a range between 185° and 260°. In other embodiments, the second angle W2 can be omitted entirely, or it can be, for example, at least 30°, preferably at least 60°, and particularly preferably at least 110°.

[0113] It is still in Fig. 3a shows that the contact lamellae 5 extend obliquely inwards, or obliquely towards the contacted part 11, from the base element 4 in their rear section 6. A third angle W3 between the contact lamella 5 and the insertion direction E can be, for example, between 5° and 40°, preferably between 10° and 35°.

[0114] Fig. Figure 3b shows the contact element 9 in the second position P2 (solid lines - the previous first position P1). Fig. (Figure 3a is shown with dashed lines). The front end 31 of the contacting part 11 is inserted into or arranged in the bottom recess 27 of the base 26 of the contact chamber 14. The bottom recess 27 can, for example, have a slight interference (e.g., up to 500 µm, preferably up to 250 µm) with respect to the front end 31. Alternatively, an interference fit can be formed, i.e., the front end 31 has a slight interference with respect to the diameter of the bottom recess 27. In this way, the contact element 9 is guided and / or secured in the radial direction 9, thus advantageously ensuring permanent and reliable contact even under adverse operating conditions (e.g., vibration loads, thermal cycling, etc.).

[0115] The first position P1 and the second position P2 are, by way of example, located along the insertion direction E by a maximum of 5 mm apart, preferably by a maximum of 2 mm apart and most preferably by a maximum of 1 mm apart.

[0116] In other words, the second position P2 is spaced away from the first position P1 by a second distance D2 (viewed along the insertion direction E).

[0117] In the second position P2, the collar 12 of the head section 10 mechanically contacts the front section 7 of the contact lamellae 5 in such a way that the contact lamellae 5 are displaced along the radial direction R towards the contacted part 11 and thereby electrically contact the contacted part 11 in the contact section 13 of the contacted part 11 and, in particular, clamp the contacted part 11 between themselves (especially when viewed along the radial direction R).

[0118] In other words, the collar 12 is pressed onto the end face 33 of the contact lamellae 5, causing the contact lamellae 5 to deflect or tilt radially inwards towards the contacted part 11 in the radial direction R. This results in the contacted part 11 being subjected to a contact normal force in the contact section 13 by means of the contact lamellae 5, which, in this example, acts essentially in the radial direction R.

[0119] In this embodiment, it is provided by way of example that in the second position P2 the contact lamellae 5 contact the contact section 13 with a contact normal force in radial direction R of at least 1N, preferably of at least 5N.

[0120] In addition to the contact between connector 1 and mating connector 2 via the contact lamellae 5 in the contact section 13 of the contacted part 11, further current conduction paths are formed, which run via the end face 33 in the front section 7 of the contact lamellae 5 to the underside 35 of the collar 12. These current conduction paths are formed along the axial direction.

[0121] This results in a particularly reliable and secure connection. On the one hand, the number of contact points is significantly increased (here: doubled). On the other hand, the essentially orthogonal orientation of the contact points provides a connection that is particularly robust against mechanical influences from various directions (e.g., vibrations or thermal cycling) and against manufacturing tolerances.

[0122] In Fig. Figure 3b further shows that the base element 4, in the second position P2, is supported against the outer wall 15 of the contact chamber 14. This support is provided here primarily along the radial direction R. The axial pressure exerted on the contact lamellae 5 by the collar 12 allows the contact lamellae 5 to push, tilt, or displace the base element 4 radially outwards. This displacement is limited by the support against the outer wall 15, against which the base element 15 rests. This stabilizes the lamella cage 3. The normal contact force of the contact lamellae 5 on the contact section 13 and / or on the collar at the end face 33 can thus be maintained or precisely controlled.

[0123] In purely schematic terms, an optional locking element 28 is also shown, which secures the second position P2 against loosening. The locking element 28 is represented here only symbolically or schematically as a clamp that clamps the contact element 9 and the contact chamber 14 together, thus preventing connector 1 and mating connector 2 from separating.

[0124] Fig. Figure 4a shows a schematic cross-section through another connector arrangement 100 in the second position P2, wherein this connector arrangement 100 is similar to that from Fig. 3b is trained.

[0125] The connector assembly 100 made of Fig. However, 4a differs from the one in Fig. 3b, among other things, by providing a groove 16 in the collar 12 of the contact element 9 on the side facing the lamellar cage 3, which extends between the contacted part 11 and an edge 17 of the collar 12. In other words, a groove 16 is formed in the underside 35 of the collar 12. This allows, for example, the end face 33 of the contact lamellae 5 to be advantageously captured and thus arranged in the correct radial position on or in the collar 12, for example, already in the first position P1. If one or more contact lamellae 5 are damaged or bent, i.e., if the end face 33 is not in the correct radial position, or if the contact element 9 is placed slightly radially offset, then (in particular radial) self-centering of the bent contact lamella(s) 5 in the groove 16 and / or radial self-centering of the contact element 9 can advantageously occur.If one or more contact lamellae 5 are significantly bent, the contact element 9 may become misaligned, as some contact lamellae 5 are trapped in the groove 16, while others protrude from the underside 35 of the collar 12. Such misalignment can serve as an indicator of a problem for an installer or machine. This can thus advantageously improve assembly quality.

[0126] In this exemplary embodiment, an inner groove wall 18 is flush with a contact part outer wall 19. This allows the contact lamellae 5 to lie particularly close to the contact part 11 and makes it particularly easy to achieve a high normal contact force in the contact section 13.

[0127] In this exemplary embodiment, in the second position P2, the contact lamellae 5 with their front sections 6 are arranged in the groove 16. In this way, the contact lamellae 5 are advantageously secured against (radial) slippage out of the contacting position, e.g., even under strong vibration loads or thermal cycling. It is therefore not possible for the end face 33 to be displaced radially outwards in the short term (e.g., by an impact) and for the contact lamellae 5 to change its bend (e.g., into a bistable second state in which the contact lamellae 5 folds radially outwards at the level of the contact section 13).

[0128] In this exemplary embodiment, the contact lamellae 5 contact the groove 16 on at least two sides. These at least two sides are preferably spaced apart from each other by at least 30° (this refers to an angle in the depicted plane, not an angle along the direction of rotation U). One contact side is, for example, the inner wall 18 of the groove. Another contact side is, for example, the bottom 30 of the groove. In this exemplary embodiment, the outer wall 20 of the groove is also contacted by the contact lamella 5. Due to the axial force exerted by the contact element 9, the front section 6 of the contact lamellae 5 is compressed in the groove 16 in the second position P2 and fills the groove 16 significantly more in the second position P2 than in the first position P1.In this way, the contact area between contact lamellae 5 and contact element 9 is significantly increased, thereby (significantly) increasing the current-carrying capacity of the connector assembly 100 and reducing the contact resistance. Furthermore, this advantageously increases the number of contact points. This, in turn, improves the redundancy of contact points, thus better protecting the connector assembly 100 against failures.

[0129] The optional locking element 28 for securing the second position P2 is shown here only as an example of a slide which can be guided in the second position P2 through locking recesses 36 in the base 26 of the contact chamber 14 and through a recess 32 in the contact part 11 in the area of ​​the base recess 27.

[0130] Fig. Figure 4b shows a schematic cross-section through another connector arrangement 100 in the second position P2, wherein this connector arrangement 100 is similar to that shown in Fig. 4a is formed, i.e., it has a groove 16 in the head section 10.

[0131] In this exemplary embodiment, the groove 16 extends obliquely outwards along the outer wall 20 of the groove facing the edge 17. This allows the radial tilting or displacement of the contact lamellae 5, forced by the axial force (through the collar surface), to be supplemented or supported by a positive-locking component. The oblique outer wall 20 of the groove acts as a cam or cam guide, causing a precisely defined radial displacement of the front section 7 of the contact lamellae 5 in the radial direction R towards the contacted part 11 when the contact element 9 moves axially along the insertion direction E.

[0132] In this exemplary embodiment, it is provided that the first angle W1 of the groove outer wall 20 with respect to the insertion direction E lies in a range between 2° and 45° (i.e. a range of 2°-45°) or in a range between 3° and 15° (i.e. a range of 3°-15°).

[0133] This means that when the contact element 9 is moved from the first position P1 to the second position P2 (i.e. by a distance corresponding to the second distance D2, see Fig. 3a and Fig. 3b) In addition to the axial force, it is ensured that the contact lamellae 5 move a defined distance in the radial direction R towards the contacted part 11 and that the desired normal contact force is thereby applied by the contact lamellae 5 in the contact section 13. Furthermore, it is ensured that a gap 29, optionally present in the first position P1 (see Fig. 3a) between contact lamellae 5 and contacted part 11.

[0134] The optional locking element 28 is, in the exemplary embodiment of Fig. 4b analogous to the locking element from Fig. 3b formed (as a kind of bracket).

[0135] The Fig. 5a and Fig. Figure 5b shows schematic cross-sections through another connector arrangement 100 with the mating connector 2 in the first position P1 ( Fig. 5a) or in the second position P2 ( Fig. 5b).

[0136] In this embodiment, the lamellar cage 3 is directly connected to the first component 50; a separate contact chamber 14 is not provided here, but could optionally be included.

[0137] The contact element 9 is received or arranged in a mating connector housing 61. Here, by way of example, it is mounted or arranged at its head section 10 in a contact element chamber 62 and preferably secured with respect to the axial direction.

[0138] The cross-section shown reveals two spaced-apart locking elements 52, arranged on the first component 50 and projecting from it towards the mating connector 2. The lamellar cage 3 is positioned between them. The locking elements 52 are shown here with undercuts as an example.

[0139] In the cross-section shown, two locking elements 63 can be seen on the mating connector housing 61. These elements project from the housing 61 in the direction of the connector 1 and each has a hook element. The locking elements 63 can be designed as elastically reversible locking lances or clip elements (especially along the radial direction R). The contact element 9 is arranged between the locking elements 63.

[0140] In the Fig. In the first position P1 shown in Figure 5a, the counter-locking elements 63 can rest on the locking elements 52, thus providing, for example, advantageous haptic feedback for a technician upon reaching the first position P1. In other embodiments, it may be provided, for example, that a captive connection between connector 1 and mating connector 2 is formed as soon as (or even before) the first position P1 is reached, so that the assembly can be transported in this state.

[0141] The counter-latching elements 63 can, for example, slide past the undercuts of the latching elements 52 on their way from the first position P1 to the second position P2 (deflection radially outwards in the illustrated exemplary embodiment) and, in the second position P2, be elastically and reversibly springed back radially inwards to their initial position, so that their hook elements engage behind the undercuts of the latching elements 52. In this way, an unintentional release of the contact element 9 from the second position P2 towards the first position P1 is prevented. Latching elements 52 and counter-latching elements 63 thus form a type of locking element 28.

[0142] The lamella cage 3 is shown here as an example analogous to the lamella cage from Fig. 2b trained.

[0143] Collar 12 has, analogous to collar 12 of the Fig. 3a and Fig. 3b a flat or planar underside 35 (no groove 16 present).

[0144] The contact element 9 has P1 in the first position ( Fig. 5a) by way of example a radial play with respect to the contact lamellae 5, here by way of example a gap 29 is formed between contacted part 11 and at least one contact lamella 5. In the second position P2 ( Fig. 5b) The contact lamellae 5 are in (mechanical) contact with the underside 35 of the collar 12 at or in their front section 7. They are compressed by the axial force exerted by the collar 12 (between the collar 12 and the base element 4) and are thereby displaced in the radial direction R towards the contacted part 11, which they electrically contact in the contact section 13 and, in particular, subject to a defined normal contact force. They can, for example, clamp the contacted part 11 between themselves.

Claims

[1] Connector arrangement, in particular for high current and / or high voltage applications, comprising the connector arrangement (100): -- a connector (1); -- a mating connector (2) for connecting to the connector (1); wherein the connector (1) has a lamellar cage (3) with a base element (4) and with a plurality of contact lamellae (5), wherein the contact lamellae (5) -- are connected to the base element (4) in a rear section (6), -- project towards the mating connector (2) from the base element (4) and -- have a front section (7) facing the mating connector (2), wherein the mating connector (2) has a one-piece designed contact element (9) with a head section (10) and a contact part (11), wherein the contact part (11) protrudes from the head section (10), wherein the head section (10) has a collar (12) which extends in a radial direction (R) beyond the contacted part (11), wherein the contact element (9) and / or the mating connector (2), in particular in the state connected to the connector (1), is displaceable between a first position (P1) and a second position (P2), in particular along an insertion direction (E), where in the first position (P1) -- the contact element (9) and / or the mating connector (2) can be displaced along the insertion direction (E) with a force of less than 5N, in particular without force. and / or -- a radial play is formed between the contact lamellae (5) and the contacted part (11), wherein in the second position (P2) the collar (12) of the head section (10) mechanically contacts the front section (7) of the contact lamellae (5) such that the contact lamellae (5) are displaced along the radial direction (R) towards the contacted part (11) and thereby electrically contact the contacted part (11) in a contact section (13) of the contacted part (11) and in particular clamp the contacted part (11) between them. [2] Connector arrangement according to the preceding claim, wherein in the second position (P2) the contact lamellae (5) contact the contact section (13) with a contact normal force in radial direction (R) of at least 1N, preferably at least 5N. [3] Connector arrangement according to one of the preceding claims, wherein the base element (4) of the lamellar cage (3) is formed as a circumferentially closed element, in particular as a ring-shaped closed element. [4] Connector arrangement according to one of the preceding claims, wherein the first position (P1) and the second position (P2) are separated by at most 5mm along the insertion direction (E), preferably by at most 2mm and particularly preferably by at most 1mm. [5] Connector arrangement according to one of the preceding claims, wherein in the first position (P1) the radial clearance between the contact lamellae (5) and the contacted part (11) is in a range between 5µm and 200µm or in a range between 20µm and 100µm. [6] Connector arrangement according to one of the preceding claims, wherein the contact lamellae (5) extend from the base element (4) at least partially obliquely towards the contacted part (11). [7] Connector arrangement according to one of the preceding claims, wherein the connector (1) has a contact chamber (14) with an outer wall (15), wherein the lamellar cage (3) is arranged in the contact chamber (14), wherein the base element (4) is arranged inside the contact chamber (14) adjacent to the outer wall (15). [8] Connector arrangement according to the preceding claim, wherein the base element (4) is supported in the second position (P2) on the outer wall (15) of the contact chamber (14), in particular in the radial direction (R). [9] Connector arrangement according to one of the preceding claims, wherein a groove (16) is provided in the collar (12) of the contact element (9) on the side facing the lamellar cage (3), which is arranged in particular between the contact part (11) and an edge (17) of the collar (12), wherein in particular an inner wall (18) of the groove is flush with an outer wall (19) of the contact part. [10] Connector arrangement according to the preceding claim, wherein the groove (16) runs obliquely outwards on an outer wall (20) of the groove facing the edge (17), wherein in particular a first angle (W1) of the groove outer wall (20) with respect to the insertion direction (E) lies in a range between 2° and 45° or in a range between 3° and 15°. [11] Connector arrangement according to the preceding claim, wherein in the second position (P2) the contact lamellae (5) with their front sections (6) are arranged in the groove (16), wherein the contact lamellae (5) contact the groove (16) in particular on at least two sides. [12] Connector arrangement according to one of the preceding claims, wherein the contact lamellae (5) in the front section (6) are bent in a radial direction (R) away from the contacted part (11), in particular relative to the insertion direction (E) by a second angle (W2) of at least 30°, preferably of at least 60° and particularly preferably of at least 110°.

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