Sealed plug connection with at least two-part contact element construction

Abstract

The invention relates to a plug connection for providing a detachable, electrically conductive connection, comprising a plug connector with a plug connector housing and a plug connector mating connector with a plug connector mating connector housing, wherein at least one contact element is arranged within the plug connector and the plug connector mating connector, wherein the plug connection is sealed against external environmental influences, wherein the at least one contact element is essentially constructed in two parts and the sealing against external environmental influences is achieved by a multi-stage sealing system.

Description

[0001] The invention relates to a plug connection for providing a detachable, electrically conductive connection, comprising a plug connector with a plug connector housing and a plug connector mating connector with a plug connector mating connector housing, wherein at least one contact element is arranged within the plug connector and the plug connector mating connector, wherein the plug connection is sealed against external environmental influences.

[0002] Connectors in a wide variety of designs and variants are used to make contact or create detachable, electrically conductive connections. Connector solutions are available in a wide range of configurations, for example, with regard to the number of poles, electrical performance, and conditioning for a wide range of external influences such as humidity, temperature, corrosive media, or mechanical stress.

[0003] Depending on the environmental conditions and the resulting impacts on connectors, it must be ensured that the contacting task is performed permanently, reliably, and without failure. To achieve this goal, protection classes have been defined, which are expressed by IP codes (IP = International Protection) and are based on test procedures for various environmental conditions.

[0004] Connectors, especially those designed to meet various protection levels or IP codes (IP classes), are often enclosed, housed, partially or fully sealed, or even shielded by housings. Other requirements such as sealing the contact elements, strain relief for the connected electrically conductive cables and wires, multiple contacts in a confined space, and so on can result in further special requirements for connector housings.

[0005] For connectors with axially aligned connector partners or those positioned at an angle to each other—so-called right-angle connectors—design solutions are available. These connector plugs comprise two or more connector housing parts that are assembled into a single connector housing by joining them together. In addition to the costly multi-part design, multiple sealing levels are an inevitable consequence, which poses the potential and possible risk of leaks.

[0006] An example of sealed plug connection solutions is shown in DE 10 2014 106 355 A1. It presents a circular connector comprising a metallic housing with a cylindrically shaped hollow receiving section for receiving a matching plastic contact insert with a cylindrically shaped retaining and sealing section. The inner wall in the region of the receiving section is formed with at least one annularly circumferential locking element for sealing engagement with the wall of the retaining section. The locking and sealing element functions both as a mechanical connection between the contact insert and the circular connector and also seals through a sealing function, since a completely annular seal is formed as a result of the locking elements of the locking and sealing element digging into the wall of the contact insert.

[0007] DE 10 2014 112 045 B4 describes the sealing of a connector by means of a separate seal. It describes a connector housing with a sealing element for sealing a stranded conductor bundle for a connector, comprising a substantially cylindrical sealing body with at least two stranded conductor channels, preferably a plurality of different stranded conductor channels with different cross-sections, wherein the respective stranded conductor channels taper at least in one inner section or extend into the stranded conductor channel and thereby have bulges that reduce or taper the cross-section. The sealing element is designed such that the pressing forces act on the stranded conductors at suitable passages in the stranded conductor channels, and further pressing forces continue to occur as soon as the sealing element is inserted into a designated connector or a receiving space of a connector housing.

[0008] If connectors are used in maritime environments, the requirements for sealed connector solutions are particularly high.DE 10 2007 021 536 B4 presents a waterproof connector with closely spaced plug contacts, comprising an outer housing having a terminal receiving part and a wire seal fitting part, wherein the terminal receiving part has a plurality of terminal receiving chambers, and wherein the terminal receiving chambers receive a plurality of terminals connected to electric wires at a first pitch, wherein the wire seal fitting part has a wire seal, wherein the wire seal comprises: a lead-out part for leading the electric wires to the outside, a sealing member arranged between the terminal receiving part and the led-out part to allow the plurality of electric wires to pass through, and a pitch adjusting part arranged between the terminal receiving chambers and the sealing member for adjusting the first pitch to a second pitch.

[0009] In addition to the particularly important requirement in maritime environments for highly reliable sealing solutions for plug-in connectors when mated together, aggressive environmental conditions such as salty sea air, humidity, hot gases, etc. can affect the plug-in connector. Especially when plug-in connectors are not mated together, this means that direct impact on the contact elements is possible, because the sealing function of the plug-in connector is only available when mated together. This can cause contact elements to be attacked or corroded much more quickly on their surfaces, resulting in a reduced service life of the plug-in connector and / or an unreliable functionality regarding the detachable transmission of electrical energy.

[0010] The object of the invention is to seal detachable, electrically conductive plug connections very reliably against external environmental influences when plugged in and at the same time to increase their service life.

[0011] To solve the problem, the invention proposes contact elements with an essentially two-part structure and combines this contact structure with a multi-stage sealing system within the connector.

[0012] The essentially two-part contact element according to the invention is formed by a first contact element and at least one second contact element. The first contact element is secured within a connector plug housing or a connector mating connector housing. The second contact element can be configured as a plug contact pin or a plug contact socket. The contact elements are detachably connected to one another, so that in the event of wear, corrosion, or other service-impairing damage to the second contact element, the latter can be removed through the detachable connection to the first contact element and replaced with a new second contact element. By replacing only the damaged second contact element, the plug connection or the respective connector plug or connector mating connector can continue to be used, thus significantly increasing its service life.

[0013] In order to realize the essentially two-part structure of the contact elements within a plug connection sealed against environmental influences, the invention provides a multi-stage sealing system.

[0014] The first sealing system component is formed by a seal which radially seals the first contact part element against the connector plug housing or the connector mating plug housing.

[0015] A second sealing system component is a potting compound, which, in its flowable state prior to curing, is introduced behind the first contact element in the plug-in direction and seals radially and axially. This not only creates a second sealing effect alongside the first sealing system component, but also verifies the correct positioning and sealing effect of the first sealing system component by pouring the potting compound.A further advantage of the combination of the first and second sealing system components for sealing the first contact element relative to the connector plug housing or the connector mating connector housing is that the unmated connector plug or connector mating connector is sealed to at least IPX7, so that power electronics arranged, for example, within the respective connector plug housing or connector mating connector housing or other components sensitive to environmental influences are protected.

[0016] The third sealing system component is formed by a circumferential seal on the second contact part element, which seals radially against the connector plug housing or the connector mating plug housing.

[0017] A further sealing system component with a sealing function between the connector plug housing and the connector mating plug housing can be provided by a circumferential seal with a radial sealing effect.

[0018] The invention is explained in more detail below using an exemplary embodiment in conjunction with the figures. In the figures: Fig. 1 a perspective view of the connector plug (upper view) and the connector mating plug (lower view) of the connector; Fig. 2 the plug connection in a non-mated situation in different views; Fig. 3 the sectional view AA of the connector according to the section line of the side view from Fig. 2 in a non-assembled situation; Fig. 4 the detail X of the connector according to the detailed view from Fig. 3 in a non-connected situation.

[0019] Fig. Figure 1 shows a perspective view of the connector plug 10 (upper illustration) and the connector mating plug 20 (lower illustration) of the connector 1. For the illustration, an exemplary embodiment with two contact elements 30 each has been selected.

[0020] Fig. 2 shows the connector 1 in an unmated situation in different views - front view, side view, top view and bottom view.

[0021] Fig. 3 the sectional view AA of the connector 1 according to the section line of the side view of Fig. 2 in the unmated state. The contact elements 30 are essentially constructed in two parts and each comprise a first contact element 31 and at least one second contact element 32. The first contact element 31 is secured within the connector plug housing 11 or the connector mating connector housing 21, for example, by a snap connection. The second contact element 32 can be designed as a plug contact pin 34 or a plug contact socket 33, depending on its positioning in the connector 1.

[0022] The contact elements 31, 32 are detachably connected to one another. In the exemplary embodiment shown, a threaded pair is used, i.e., the connection is a screw connection. For assembly to establish the connection between the contact elements 31, 32, it is advantageous if the first contact element 31 is secured in the connector plug housing 11 or the connector mating plug housing 21 with an anti-twist device (not shown).

[0023] Fig. 4 includes the detail X of the connector 1 according to the detailed view of Fig. 3 in a non-mated state. In order to be able to use the illustrated essentially two-part contact element structure formed by a first contact element 31 and at least one second contact element 32 in sealed connectors 1, a multi-stage sealing system 40 is provided according to the invention.

[0024] The first sealing system component 41 is formed by a seal, here designed as an O-ring, which radially seals the first contact element 31 relative to the connector plug housing 11.

[0025] In the plugging direction, behind the first contact element 31, a potting compound with sealing properties is provided in the connector plug housing 11, which constitutes the second sealing system component 42. This second sealing system component 42 seals the first contact element 31 axially and radially from the connector plug housing 11 in addition to the first sealing system component 41 and ensures a media-tight seal even if the first sealing system component 41 becomes leaky or fails.

[0026] The potting compound is liquid, flowable, or pasty during processing and thus when introduced into the connector plug housing 11, so that the potting compound also flows into the gap between the contact element 31 and the connector plug housing 11, ensuring a particularly media-tight seal. In addition, the pouring of the potting compound during processing also checks whether the first sealing system component 41 is correctly seated and sealing, as otherwise the potting compound would leak out there.

[0027] In particular, if the detachable connection of the contact elements 31, 32 is formed by a threaded pair, a third sealing system component 43 may be required, since threaded pairs cannot seal. The third sealing system component 43 is formed by a circumferential seal on the second contact element 32, which radially seals against the connector housing 11. In the illustrated embodiment, an O-ring was selected for the third sealing system component 43.

[0028] The sealing system 40 with the first and second and third sealing system components 41, 42, 43 provides a particularly high-quality seal for the essentially two-part structure of the contact elements 30 and is capable of achieving a sealing level of IPX7, even in the unmated state of the plug connection 1, for example for power electronics arranged within the plug connector housing 11 or other components sensitive to environmental influences (not shown).

[0029] Furthermore, it is possible to supplement the sealing system 40 with the first, second, and third sealing system components 41, 42, 43 with additional sealing system components. For example, as shown, a fourth sealing system component 44 with a sealing function can be provided between the connector plug housing 11 and the connector mating plug housing 21 by means of a circumferential seal with a radial sealing effect. The circumferential seal can be designed with three lips, thus achieving a particularly reliable seal and simultaneously providing form and position tolerance compensation of up to 3 mm in the axial direction. List of reference symbols 1 plug connection 10 connector plugs 11 Connector plug housing 20 connector mating connectors 21 Connector mating connector housing 30 contact element 31 first contact part element 32 second contact element 33 plug-in contact socket 34 plug contact pin 40 Sealing system 41 first sealing system component 42 second sealing system component 43 third sealing system component 44 fourth sealing system component QUOTES CONTAINED IN THE DESCRIPTION

[0000] This list of documents submitted by the applicant was generated automatically and is included solely for the convenience of the reader. This list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions. Cited patent literature

[0000] DE 10 2014 106 355 A1

[0006] DE 10 2014 112 045 B4

[0007] DE 10 2007 021 536 B4

[0008]

Claims

[1] Plug connection (1) for providing a detachable, electrically conductive connection, comprising a plug connector (10) with a plug connector housing (11) and a plug connector mating connector (20) with a plug connector mating connector housing (21), wherein at least one contact element (30) is arranged within the plug connector (10) and the plug connector mating connector (20), wherein the plug connection (1) is sealed against external environmental influences, characterized by that the at least one contact element (30) is essentially constructed in two parts and the sealing against external environmental influences is effected by a multi-stage sealing system (40). [2] Plug connection (1) according to claim 1, characterized by that the at least one contact element (30) has a first contact sub-element (31) and at least one second contact sub-element (32). [3] Plug connection (1) according to claim 2, characterized bythat the contact elements (31, 32) are detachably connected to one another. [4] Plug connection (1) according to claim 3, characterized by that the detachable connection of the contact elements (31, 32) is a threaded pair. [5] Plug connection (1) according to claim 2, characterized by that the first contact part element (31) is fixed within the connector plug housing (11) and / or the connector mating plug housing (21). [6] Plug connection (1) according to claim 5, characterized by that the first contact element (31) is secured against rotation and / or releasably fixed. [7] Plug connection (1) according to claim 1, characterized by that the multi-stage sealing system (40) is formed by a first sealing system component (41) and at least one third sealing system component (43) for sealing the at least one contact element (30). [8] Plug connection (1) according to claim 7, characterized bythat the first and third sealing system components (41, 43) are each an O-ring. [9] Plug connection (1) according to claim 7, characterized by that the multi-stage sealing system (40) is supplemented by a second sealing system component (42). [10] Plug connection (1) according to claim 9, characterized by that the second sealing system component (42) is a potting compound. [11] Plug connection (1) according to claim 7, characterized by that the multi-stage sealing system (40) is supplemented by a fourth sealing system component (44). [12] Plug connection (1) according to claim 11, characterized by that the fourth sealing system component (44) is a circumferential housing seal between the connector plug (10) and the connector mating plug (20).

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