Shielded high-voltage connector with one-piece shield sleeve

Abstract

The invention relates to an angled connector (10) with an angled housing (10) comprising a first housing section (10a) extending in a connection direction X and a second housing section (10b) extending in a plug-in direction Y, further comprising an assembly (B) consisting of a cylindrical contact carrier (20) and two high-voltage contacts (30) received therein and surrounded by the contact carrier material, wherein the assembly (B) is surrounded by a shield sleeve (40) formed in one piece and / or in one piece from a shielding sheet (41), wherein the shield sleeve (40) is formed as an angled sleeve from two hollow cylindrical shield sleeve sections (40a, 40b) from the shielding sheet (41) and are connected to each other at a common butt edge (42) extending obliquely to the plug-in direction Y.

Description

[0001] The invention relates to a connector according to the preamble of claim 1, in particular an HV connector with a shield and a method for producing a shielding sleeve.

[0002] A shield contact element of this type is known, for example, from DE 20 2013 006 413 U1. For contacting a cable shield with an electrical device, in particular its housing made of a metallic material, a contact sleeve is known that has a hollow cylindrical base body that can be slid over the cable.

[0003] Several spring tongues are distributed around the circumference of both ends of the hollow-cylindrical base body of the contact sleeve. These spring tongues make electrical contact with the cable shielding, particularly its braided shielding, when a cable gland is slid over them. The other spring tongues are also contacted with a stop when the cable gland has also been slid over the cable and positioned in its final position.

[0004] Such a design of the shield contact element is used for high-voltage cables for electric or hybrid vehicles, because such high-voltage cables require shielding in order to protect the remaining on-board network electronics, which operate in the low-voltage range (for example 12, 24 or 48 volts), from interference due to the voltages used in the range of typically 300 volts to 800 volts.

[0005] This requires the cable shielding to be looped through to the electrical device, particularly its metal housing, which also provides shielding. Sensors, actuators, or the like are connected to the electrical device via the cable. This also requires the known shielding contact element to be looped through this shielding when mounting the cable to the electrical device, for example, by means of a plug-in connector.

[0006] However, with the known shielding contact element there is a risk that, due to the individual spring tongues protruding outwards, these spring tongues will be bent during assembly, but also during storage, so that either assembly can no longer be carried out at all or the shielding is insufficient if the shielding contact element has been assembled with the spring tongues bent in an impermissible manner.

[0007] DE 10 2015 226 034 A1 stipulates that the spring elements are configured as external spring elements located at one end of the hollow-cylindrical base body for contacting the electrical device, and as internal spring elements located at the other end of the hollow-cylindrical base body for contacting the cable shielding. The advantage of this design of the shield contact element is that the internal spring elements no longer face outward, i.e., outside the outer surface of the hollow-cylindrical base body or protrude from it, effectively preventing damage.

[0008] However, there is also a need for so-called angled, particularly 90° angled HV connectors, especially for space-saving installation in vehicles. Due to the angled design, shielding has so far been inadequate. On the one hand, the state of the art does not offer a suitable solution for an angled connector, and on the other hand, the solutions available on the market are inadequate with regard to shielding requirements.

[0009] DE 10 2006 012 194 A1 discloses a shielded connector in an angled design, which comprises an assembly including a contact carrier surrounded by a shielding sleeve, in which contact partners are arranged at the end of electrical conductors of a cable having a shielding braid. A shielding housing formed by the shielding sleeve and a shielding housing extending from one end of the cable extends from the end of the cable to the contact carrier. Such a shielded connector enables signals, in particular high-frequency signals, to be transmitted via the electrical conductors of the cable and the contact partners arranged at their ends.When mating a connector with a mating connector, it is not only necessary to mate the contact partners of the connector and the corresponding mating connector, but it must also be ensured that the transmitted signals are consistently shielded against interference. At the same time, continuous shielding along the cable and in the area of ​​the connector connection must ensure that high-frequency signals are prevented from being radiated outward by the electrical conductors. For this purpose, a multi-part shielding solution is proposed.

[0010] This multi-part shielding housing design is extremely complex to manufacture, as the two halves of the shielding housing that must be connected to each other have a delicate geometry. Furthermore, the openings through which the hot melt adhesive must be introduced into the interior of the shielding housing are disadvantageous from a high-frequency perspective, as these openings do not provide sufficient shielding. As a result, interference signals can penetrate the interior of the connector through these openings or even escape to the outside. Thus, the required high-frequency sealing (shielding) is not satisfactorily ensured.

[0011] EP 2 777 097 B1 discloses a one-piece shielding solution which, however, is designed to have a slot which is essential for assembly. A further disadvantage is that a press fit must be created around the slot in the shielding housing, with one end of the cable or a prepared end region of the cable shielding braid being arranged in the region of the compressed slot. Furthermore, a crimp sleeve is additionally arranged coaxially in the area of ​​the slot in the shielding housing, so that the shielding concept is again formed from two components. With this crimp sleeve, the area of ​​the shielding housing in which the slot is located can be contacted with the shielding braid. In particular, the crimp sleeve then has the effect of closing off the remaining slot in the shielding housing at high frequencies.

[0012] Further technical concepts for shielding solutions are known from the documents DE 10 2020 116 736 A1, US 2 553 083 A, DE 25 34 111 B2, DE 20 2007 005 264 U1, US 2009 / 0 017 678 A1 and DE 10 2018 101 764 A1.

[0013] The invention is therefore based on the object of providing a shielded connector and a method for producing a shielding sleeve that avoids the disadvantages described. In particular, the aim is to ensure improved assembly compared to the prior art with good shielding effectiveness, while simultaneously simplifying the manufacture of the connector and reducing the number of parts. A further object of the present invention is to provide a repair option so that disassembly is possible without causing damage.

[0014] The object of the invention is achieved by means of the features of claim 1 and a method according to claim 10.

[0015] A basic idea of ​​the invention is to provide a specially designed one-piece, preferably one-piece, in particular angled shielding sleeve, which realizes the shielding of the HV connector in the area of ​​the shielding sleeve without further shielding elements.

[0016] According to the invention, a shielded connector in an angled design is therefore provided, with an angled housing, having a first housing section which preferably extends in a plug-side connection direction X and a second housing section which extends in a plug-in direction to a separation point Y, further having an assembly comprising a contact carrier and two HV contacts (contacts) received therein and surrounded by the contact carrier material, wherein the assembly is surrounded by a shielding sleeve formed integrally and / or in one piece from a shielding plate, wherein the shielding sleeve is formed as an angled sleeve from two hollow-cylindrical shielding sleeve sections from the shielding plate and these are connected to one another at a common abutting edge each running obliquely to the plug-in direction Y. This can preferably be done by welding, such as ultrasonic welding. Other connection methods are also possible.

[0017] In a preferred embodiment of the invention, the two shielding sleeve sections comprise at least one connecting area (e.g., a tab, web, hinge) formed integrally from the shielding plate. This serves the purpose of bending the two shielding sleeve sections around this connecting area into the desired final shape.

[0018] A solution in which the said connecting area is designed as a narrow, bendable sheet metal web is therefore advantageous. It has therefore proven advantageous if the shielding sleeve is formed by forming two cylindrical shielding sleeve sections, each with slanted abutting edges, from the shielding sheet. These are then bent along a connecting section connecting the two shielding sleeve sections until the slanted abutting edges touch.

[0019] In a further advantageous embodiment of the invention, each shielding sleeve section is provided with a plurality of circumferentially arranged shielding contact elements, each of which preferably protrudes from the outer contour of the shielding sleeve sections. These elements serve to transfer the shield to an adjacent component. The shielding contact elements are preferably connected to the shielding plate on one side and are elastically deflectable at the opposite end, where they protrude with a contact section.

[0020] In a further advantageous embodiment of the invention, the shielding sleeve protrudes from the housing on one or both sides, particularly with the area(s) containing the shielding contact elements. For this purpose, a separation point is specifically provided so that a contact part with two plug contacts can be inserted into the plug-side opening of the housing. This option also allows for later disassembly and accessibility for repairs.

[0021] At the interface, a flange on the housing with fastening elements (e.g., openings) can advantageously be provided for mounting the housing at a separation point (e.g., a wall). The mating connector can then be inserted into the housing from the rear.

[0022] The connector therefore has two separable sides.

[0023] In a further advantageous design, the two HV contacts are angled and provided with a blade or flat contact section on the plug-in side extending in the plug-in direction Y. It is preferred if the dimensions and length of the blade or flat contact sections are determined such that the HV contacts can be fully inserted and positioned in an assembly position through the opening of the shielding sleeve.

[0024] A further aspect in addition to the shielding sleeve and the connector relates to a method for producing a shielding sleeve for a shielded connector with the following steps: a. Punching a basic shape from a shielding plate having two flat sections with a connecting web in between, wherein the flat sections each form mutually facing abutting edges which are spaced apart from one another in the non-formed state; b. Forming a cylindrical shielding sleeve section from each of the two flat sections; c. Bending the shielding sleeve section around the connecting web until the correspondingly formed abutting edges make contact at the front; d. Connecting the two shielding sleeve sections, preferably by sealing them together along the abutting edges.

[0025] The connection can also be made by spot welding.

[0026] A method for producing a shielded connector (not claimed) is preferably implemented in such a way that the contact carrier with the HV contacts is inserted into the shielding sleeve and positioned, and then the housing is molded around the shielding sleeve by overmolding. For this purpose, the shielding sleeve is advantageously supported against the injection pressure.

[0027] To hold the contact carrier in position relative to the shielding sleeve, such a method for producing a shielded connector (not claimed) can further provide for securing the position by means of an embossing in the shielding plate and a corresponding groove in the plastic body. External compression can also be used.

[0028] Furthermore, the unclaimed method for producing a shielded connector is advantageously designed such that, prior to overmolding, the shielding sleeve is inserted with one end into the opening of a collar-shaped sleeve, wherein the sleeve is formed with a circumferential injection-molded collar with sealing contours. The sealing contour can be designed as a labyrinth seal.

[0029] Other advantageous developments of the invention are characterized in the subclaims or are presented in more detail below together with the description of the preferred embodiment of the invention with reference to the figures.

[0030] They show: Fig. 1 is an isometric view of the components according to an embodiment of the invention; Fig. 2 a perspective view of a shielding sleeve according to the invention; Fig. 3 a side view of a shielding sleeve according to the invention and Fig. 4 a sectional view through the assembled connector according to an embodiment of the invention.

[0031] In the following, the invention will be explained by means of the explanations of the embodiments with reference to the Fig. 1 to 4, wherein the same reference numerals in the figures indicate the same structural and / or functional features.

[0032] In the Fig. 1 shows the components of a connector 1 according to the invention in a not yet assembled configuration. The connector 1 is shown as a shielded connector in an angled design (here 90° angle) with a housing 10 that is also angled at 90°.

[0033] The housing 10 is manufactured by means of overmolding and has a first housing section 10a, which extends in a connection direction X and a second housing section 10b, which extends in a plug-in direction Y (as can be seen from the Fig. 4). Furthermore, the connector 1 has an assembly comprising a cylindrical contact carrier 20 and two HV contacts 30 accommodated therein and surrounded by the contact carrier material, wherein the assembly is surrounded by a shielding sleeve 40 formed integrally and / or in one piece from a shielding plate 41. The shielding sleeve 40 is formed as an angled sleeve from two hollow cylindrical shielding sleeve sections 40a, 40b, which are jointly formed from the shielding plate 41 and are connected to one another at a common abutting edge 42 each running obliquely to the plugging direction Y. Furthermore, in the Fig. 2 shows that the shielding sleeve sections 40a, 40b are formed integrally from the shielding sheet 41 and are integrally connected via the connecting region 44 (a narrow, bent-over sheet metal tongue). On each shielding sleeve section 40a, 40b, a plurality of circumferentially arranged shielding contact elements 45 are provided, each of which protrudes from the envelope contour of the shielding sleeve sections 40a, 40b.

[0034] In the embodiment shown, the shield contact elements 45 are connected on one side and are designed to be elastically deflectable at the opposite end.

[0035] The two HV contacts 30 are also angled and provided with a blade or flat contact section 31 on the plug-in side extending in the plug-in direction Y, so that a pluggable connection (not shown in detail) is provided at a separation point, which can be, for example, a housing wall of a device. The housing 10 also has a flange 11 at the lower end (viewed in the Y direction).

[0036] The dimensions and length of the blade or flat contact sections 31 are determined so that the HV contacts 30 can be fully inserted and positioned in an assembly position through the opening 46 of the shielding sleeve 40. The final position is shown in the sectional view according to Fig. 4 can be seen.

[0037] Before the shielding sleeve 40 is overmolded, one end is inserted into the opening of a collar-shaped sleeve 60, wherein the sleeve 60 forms an end-side circumferential injection collar 61 with sealing contours 62.

Claims

[1] Shielded connector (10) in an angled design with an angled housing (10) having a first housing section (10a) which extends in a connection direction X and a second housing section (10b) which extends in a plug-in direction Y, further comprising an assembly (B) comprising a cylindrical contact carrier (20) and two HV contacts (30) accommodated therein and surrounded by the contact carrier material, wherein the assembly (B) is surrounded by a shielding sleeve (40) formed integrally and / or in one piece from a shielding plate (41), wherein the shielding sleeve (40) is formed as an angled sleeve from two hollow cylindrical shielding sleeve sections (40a, 40b) from the shielding plate (41) and are connected to one another at a common abutting edge (42) which runs obliquely to the plug-in direction Y. [2] Shielded connector (10) according to claim 1, characterized bythat the shielding sleeve sections (40a, 40b) have at least one connecting region (44) consisting integrally of the shielding plate. [3] Shielded connector (10) according to claim 2, characterized by that the connecting area (44) is designed as a narrow, bent sheet metal web. [4] Shielded connector (10) according to one of the preceding claims, characterized by that on each shielding sleeve section (40a, 40b) a plurality of circumferentially arranged shielding contact elements (45) are provided, which preferably each protrude from the envelope contour of the shielding sleeve sections (40a, 40b). [5] Shielded connector (10) according to claim 4, characterized by that the shield contact elements (45) are connected at one side and can be elastically deflected at the opposite end. [6] Shielded connector (10) according to one of the preceding claims, characterized bythat the shielding sleeve (40) is formed by forming two cylindrical shielding sleeve sections (40a, 40b), each with oblique abutting edges (42), from the shielding sheet (41), which are bent along a connecting section (44) connecting the two shielding sleeve sections (40a, 40b) until the oblique abutting edges (42) touch. [7] Shielded connector (10) according to one of the preceding claims, characterized by that the shielding sleeve (40) protrudes from the housing (10) on one or both sides, in particular with the area or areas which have shielding contact elements (45). [8] Shielded connector (10) according to one of the preceding claims, characterized by that the two HV contacts (30) are angled and are provided with a blade or flat contact section (31) extending in the plug-in direction Y. [9] Shielded connector (10) according to the preceding claim, characterized bythat the dimension and length of the blade or flat contact sections (31) are determined such that the HV contacts can be completely inserted into an assembly position through the opening (46) of the shielding sleeve (40) and brought into position. [10] Method for producing a shielding sleeve (40) according to one of the preceding claims, comprising the following steps: a. punching a basic shape from a shielding plate (41) having two flat sections with a connecting web (44) located therebetween, wherein the flat sections each form abutting edges (42) facing one another, which are spaced apart from one another in the non-formed state; b. forming a cylindrical shielding sleeve section (40a, 40b) from each of the two flat sections; c. Bending the shielding sleeve section (40a, 40b) around the connecting web (44) until the correspondingly formed abutting edges (42) make contact at the end face; d. Connecting the two shielding sleeve sections (40a, 40b), preferably by material-locking closure along the abutting edges (42).

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