Electrical high-voltage connector

Abstract

An electrical high-voltage connector is described. The electrical connector contains an inner housing. The inner housing defines a terminal cavity designed to receive an electrical connection. A terminal position lock is attached to the inner housing to allow relative movement between an open position and a closed position. The terminal position lock extends into the terminal cavity when in the closed position. The electrical connector contains an outer housing with an outer body that defines an outer housing cavity. The outer body also defines an outer housing opening. The inner housing is held within the outer housing cavity. A lever is connected to the outer housing to allow relative movement between a pre-assembled position and an assembled position. The lever defines a lever opening.The outer housing opening is located between the connection position lock and the lever opening.

Description

Area

[0001] This revelation relates to an electrical connector. More specifically, this revelation relates to an improved high-voltage electrical connector. background

[0002] Electrical components are often connected to each other using conductive cables. Electrical connectors attached to these cables allow the components to be connected at a desired time. For example, electrical components from different sources can be assembled during the production of a larger assembly. It is desirable to provide an improved electrical connector that enables precise and easy connection of components. Summary

[0003] Several examples of electrical connectors are described.

[0004] An exemplary electrical connector includes an inner housing. The inner housing defines a terminal cavity designed to receive an electrical connection. A terminal position lock is attached to the inner housing for relative movement between an open position and a closed position. The terminal position lock extends into the terminal cavity when in the closed position. The electrical connector includes an outer housing with an outer body that defines an outer housing cavity. The outer body also defines an outer housing opening. The inner housing is held within the outer housing cavity. A lever is connected to the outer housing for relative movement between a pre-assembled position and an assembled position. The lever defines a lever opening.The outer housing opening is located between the connection position lock and the lever opening.

[0005] Another exemplary electrical connector includes a connector housing. The connector housing has a body that defines a housing cavity. The housing cavity defines a housing cavity axis. Attached to the connector housing is a connector position lock for relative movement between a pre-locked position and a locked position. The connector position lock includes a connector position lock body and a leg extending from the connector position lock body. The leg is movable relative to the connector position lock body between a hold position and a release position. The leg includes a release mechanism that engages in the connector housing to hold the connector position lock in the pre-locked position when the leg is in the hold position. The release mechanism is located at a first distance from the housing cavity axis.The connector position locking body is located at a second distance from the housing cavity axis, which is greater than the first distance.

[0006] Another exemplary electrical connector includes a housing that defines a terminal cavity. The terminal cavity extends between a contact end and a connection end. An electrical terminal is located within the terminal cavity. The electrical terminal includes a contact portion configured to engage a corresponding terminal and a connection portion configured to engage a conductor. The contact portion is located closer to the contact side of the terminal cavity than to the connection side. The connection portion is located closer to the connection end of the terminal cavity than to the contact end. The electrical terminal includes a tab on the contact portion that extends toward the connection end of the terminal cavity. A terminal position indicator is attached to the housing and engages the tab to hold the electrical terminal in the terminal cavity.

[0007] An additional understanding of these examples will be gained by the person skilled in the art from the following detailed description when he reads it in light of the accompanying illustrations. Brief description of the illustrations Fig. Figure 1 is a perspective view of an exemplary electrical connector assembly containing a first electrical connector and a second electrical connector. Fig. 2 is a perspective view of the in Fig. 1 first electrical connector shown. Fig. Figure 3 is a perspective rear view of the in Fig. 2 shown first electrical connector. Fig. Figure 4 is an enlarged perspective rear view of an inner housing of the in Fig. 3 first electrical connector shown. Fig. Figure 5 is a cross-sectional view along line 5-5 in Fig. 3. Fig. Figure 6 is a cross-sectional view along line 6-6 in Fig. 5. Fig. Figure 7 is a cross-sectional view similar to Fig. 6 and shows a connection position lock that has been moved into a closed position. Fig. 8 is an enlarged view of a connector position lock of the in Fig. 2 shown first electrical connector. Fig. Figure 9 is an enlarged cross-sectional view of a part of Fig. 5, showing a lever in a closed position and the connector position lock in a locked position. Fig. 10 is a perspective view of the in Fig. 1. Second electrical connector shown. Fig. 11 is a partial exploded view of the in Fig. 12 shown second electrical connector. Fig. 12 is a cross-sectional view along line 12-12 in Fig. 10. Fig. 13 is a cross-sectional view along line 13-13 in Fig. 12. Fig. 14 is a cross-sectional view along line 14-14 in Fig. 6. Fig. Figure 15 is an enlarged perspective view of a cable holder of the in Fig. 2 shown first electrical connector. Detailed description

[0008] Detailed reference is now made to embodiments, examples of which are shown in the accompanying figures. The following detailed description specifies numerous details to provide a comprehensive understanding of the various described embodiments. However, it will be clear to a person skilled in the art that the various described embodiments can also be implemented without these specific details. In other cases, known methods, procedures, components, circuits, and networks have not been described in detail in order to avoid unnecessarily obscuring aspects of the embodiments.

[0009] It is also understood that, although the terms "first," "second," etc., are used here in some cases to describe different elements, these elements should not be restricted by these terms. These terms are used only to distinguish one element from another. For example, a first shield could be called a second shield, and likewise a second shield could be called a first shield, without exceeding the scope of the various embodiments described. The first shield and the second shield are both shields, but they are not the same shield.

[0010] The terminology used in the description of the various embodiments described herein serves only to describe specific embodiments and is not to be understood as limiting. As used in the description of the various described embodiments and the appended claims, the singular forms "a," "an," and "the" are intended to include the plural forms unless the context clearly indicates otherwise. Furthermore, it is understood that the terms "contains," "includes," and / or "comprising," when used in this description, specify the presence of certain features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0011] The Fig. Figure 1 shows a perspective front view of an electrical connector assembly, substantially designated 10. The electrical connector assembly 10 comprises a first electrical connector, substantially designated 12, and a second electrical connector, substantially designated 14. The first electrical connector 12 is in Fig. 1 is assembled with the second electrical connector 14. Fig. Figure 2 shows a perspective front view of the first electrical connector 12 and Fig. Figure 3 shows a perspective rear view of the first electrical connector. 12.

[0012] The first electrical connector 12 includes an outer housing 16. The outer housing 16 shown is molded from plastic, but can be made from any desired material and using any desired method. The outer housing 16 includes an outer housing body 18, which defines an outer housing cavity, essentially designated 20.

[0013] The first electrical connector 12 contains an inner housing 22. The inner housing 22 shown is molded from plastic, but can be made from any desired material and by any desired process. Fig. Figure 4 shows a perspective rear view of the inner housing 22. The inner housing 22 defines a connection cavity 24, which is designed to receive an electrical connection (not shown). The inner housing 22 shown contains four connection cavities 24, but can have any number of connection cavities 24. The inner housing 22 also contains a connection position lock 26. The connection position lock 26 is in Fig. 4 attached to the inner housing 22 and shown in an open position. The depicted terminal position lock 26 is cast as part of the inner housing 22 and incorporates a film hinge (living hinge) 28. In Fig. Figure 4 shows two connection position locks 26, and in the illustrated embodiment each connection cavity 24 contains a connection position lock 26.

[0014] Fig. Figure 5 is a cross-sectional view along line 5-5 in Fig. 3. The outer housing 16 contains an inner latch 30 that engages in the inner housing 22, and the inner housing 22 is held in the outer housing cavity 20. Fig. Figure 6 is a cross-sectional view along line 6-6 in Fig. Figure 5 shows that the terminal position lock 26 is in the open position when the inner housing 22 is attached to the outer housing 16.

[0015] The first electrical connector 12 includes a lever 32 which is attached to the outer housing 16 to allow a relative movement (e.g. a relative rotational movement) between a pre-assembled position, as in the Fig. 2 and Fig. 3 shown, and a compound position, as in Fig. As shown in Figure 1, the lever 32 engages the leg 62 in the assembled position, as described in more detail here, and moves the leg into the release position. The lever 32 comprises two lever arms 34 connected by a handle 36. The lever 32 shown rests on two support bodies 38 on the outer housing 16, and the lever 32 shown is rotatable about an axis 40 relative to the outer housing 16. The lever 32 comprises two channels 42, one of which is defined in each arm 34. The second electrical connector 14 comprises two pins 44, one of which is in Fig. Figure 1 shows how to assemble the first electrical connector 12 with the second electrical connector 14. The lever 32 is moved to the open position and the second electrical connector 14 is positioned so that each of the pins 44 of the second electrical connector 14 is in one of the channels 42. The lever 32 is then moved to the closed position to engage the second electrical connector 14 with the first electrical connector 12.

[0016] In Fig. Figure 6 shows the lever 32 in its assembled position. The outer housing 16 defines an outer housing opening 46 that extends through the outer housing body 18 into the outer housing cavity 20. The lever 32 also defines a lever opening 48 that extends through it. The lever opening 48 shown is defined by one of the lever arms 34 but can be located on any part of the lever 32. When the lever 32 is in its assembled position, the outer housing opening 46 is located between the terminal position lock 26 and the lever opening 48. The terminal position lock 26 is separated from the terminal cavity 24 by the lever opening 48 shown in Figure 6. Fig. 6 shown open position in one in Fig. The terminal position lock 26 is movable in the closed position shown in Figure 7. When the terminal position lock 26 is in the closed position, it extends into the terminal cavity 24 and is configured to act as the primary locking mechanism for the electrical terminal (not shown) in the terminal cavity 24. The outer housing opening 46 and the lever opening 48 provide access to the terminal position lock 26 so that an operator can use a tool to move the terminal position lock 26 into the closed position.

[0017] As in Fig. As shown in Figure 6, the connection cavity 24 extends through the inner housing 22 and defines a connection cavity axis 50. Additionally, an imaginary insertion axis 52 extends from the connection position lock 26 through the outer housing opening 46 and through the lever opening 48. In the illustrated embodiment, the insertion axis 52 is perpendicular to the connection cavity axis 50.

[0018] The outer housing cavity 20 contains a fitting opening 54 at one outer end. The fitting opening 54 receives a corresponding electrical connector, for example, the second electrical connector 14 when the first electrical connector 12 and the second electrical connector 14 are connected together. As shown in Fig. As best illustrated in Figure 4, the first electrical connector 12 includes a cavity seal 56 on the inner housing 22. As shown in Figure 4, the first electrical connector 12 contains a cavity seal 56 on the inner housing 22. Fig. As shown in Figure 6, the cavity seal 56 is located in the outer housing cavity 20. The outer housing opening 46 is located between the pass-through opening 54 and the cavity seal 56.

[0019] As in Fig. As shown in Figure 2, the first electrical connector 12 includes a connector position lock 58. The connector position lock 58 is attached to the outer housing 16 to prevent relative movement between a Fig. 2 shown pre-locked position and one in Fig. 1 shown locked position. An enlarged perspective view of the connector position lock 58 is shown in Fig. Figure 8 shows the connector position lock 58, which is cast in plastic, but can be made of any desired material and using any desired process.

[0020] The connector position locking device 58 includes a connector position locking body 60. A leg 62 extends from the connector position locking body 60. The leg 62 is movable relative to the connector position locking body 60 between a holding position and a release position. Fig. Figure 5 shows the leg 62 in the holding position. In the holding position, a trigger 64 of the leg 62 engages in a detent 66 on the outer housing 16 to prevent the connector position lock 58 from moving into the locked position. Fig. Figure 9 is an enlarged cross-sectional view similar to that in Fig. Figure 5, showing the lever 32 in the closed position and the connector position lock 58 in the locked position. The lever 32 includes a release mechanism that engages the leg 62 and moves the leg 62 relative to the outer housing 16 into the release position. This allows the connector position lock 58 to be moved into the locked position. The connector position lock 58 includes a block 68 that engages a portion of the lever 32 when the lever 32 is in the closed position and the connector position lock 58 is in the locked position. This holds the lever 32 in the closed position.

[0021] As in Fig. As shown in Figure 5, the outer housing cavity 20 extends through the outer housing body 18 and defines a housing cavity axis 70. The trigger 64 is located at a first distance 72 from the housing cavity axis 70, the connector position locking body 60 is located at a second distance 74 from the housing cavity axis 70, and the second distance is greater than the first distance.

[0022] As in Fig. As shown in Figure 8, the connector position lock 58 includes a connector position lock latch 76. The connector position lock latch 76 engages in the outer housing body 18 to hold the connector position lock 58 in the pre-locked position relative to the outer housing body 18. The connector position lock latch 76 shown is attached to the connector position lock body 60, and the connector position lock latch 76 is located at the second distance 74 from the housing cavity axis 70.

[0023] As in Fig. As shown in Figure 8, the illustrated connector position lock 58 contains two legs 62, and each leg 62 contains a release 64. Each of the legs 62 has a similar shape, and each release 64 is located at the first distance 72 from the housing cavity axis 70.

[0024] As in the Fig. 5 and Fig. As shown in Figure 9, the connector position lock 58 is movable relative to the outer housing 16 parallel to the housing cavity axis 70 between the pre-locked position and the locked position. Fig. Figure 14 shows a cross-sectional view through the connector position lock 58 in the locked position. As previously described, the block 68 of the connector position lock 58 engages the lever 32 to hold it in the closed position. The connector position lock 58 thus prevents the lever 32 from being accidentally moved out of the closed position, for example, by vibrations of the electrical connector assembly 10.

[0025] As already described, the illustrated inner housing 22 contains four connection cavities 24. As in Fig. As shown in Figure 1, the first electrical connector 12 is attached to four cables 106, and each of the cables 106 extends into one of the connection cavities 24. As shown in Fig. As shown in Figure 6, each connection cavity 24 contains a corresponding cable seal 108, which is located between the respective cable 106 and the inner housing 22. The first electrical connector 12 shown also contains a cable holder 110, which is located between the cable 106 and the outer housing body 18.

[0026] In Fig. Figure 15 shows an enlarged perspective view of the cable holder 110. The cable holder 110 contains a C-shaped holder body 112. An inner locking element 114 and an outer locking element 116 extend outwards from the holder body 112. The holder body 112 defines a holder cavity, essentially designated 118, which extends through it. A plurality of retaining ribs 120 extend inwards from the holder body 112 into the holder cavity 118. As shown in Fig. As best illustrated in Figure 14, the inner locking mechanism 114 and the outer locking mechanism 116 engage with the outer housing body 18 to hold the cable holder 110 in a position relative to the outer housing 16. The cable 106 extends through the holder cavity 118, and the plurality of retaining ribs 120 engage with the cable 106 to hold it in position relative to the first electrical connector 12. This prevents the cable seal 108 from being moved relative to the inner housing 22 by a force exerted on the cable 106. As shown in Figure 14, the inner locking mechanism 114 and the outer locking mechanism 116 engage with the outer housing body 18 to hold the cable holder 110 in a position relative to the outer housing 16. The cable 106 extends through the holder cavity 118, and the plurality of retaining ribs 120 engage with the cable 106 to hold it in position relative to the first electrical connector 12. This prevents the cable seal 108 from being moved relative to the inner housing 22 by a force exerted on the cable 106. Fig. As shown in Figure 1, the first electrical connector 12 contains four cable holders 110, one for each cable 106.

[0027] Fig. Figure 10 shows a perspective view of the second electrical connector 14 and Fig. Figure 11 shows a partial exploded view of the second electrical connector 14. The second electrical connector 14 includes a second housing 80. The second housing 80 shown is molded from plastic, but can be made of any material and by any desired process. The second housing 80 defines a second terminal cavity 82. The second terminal cavity 82 extends through the second housing 80 between a contact end 84 and a connection end 86.

[0028] A second electrical connection 88 is located in the second connection cavity 82. The second electrical connection 88 includes a contact part 90 configured to engage with the electrical connection in the first electrical connector 12, and a connecting part 92 configured to engage with a conductor (not shown) of a cable 93. The contact part 90 is located closer to the contact end 84 of the second connection cavity 82 than the connecting end 86, and the connecting part 92 is located closer to the connecting end 86 of the second connection cavity 82 than the contact end 84. The second electrical connection 88 includes a tab 94 on the contact part 90 that extends toward the connecting end 86 of the second connection cavity 82.

[0029] The second electrical connector 14 includes a second terminal position lock 96. The illustrated second terminal position lock 96 is molded from plastic, but can be made of any material and by any desired process. The second terminal position lock 96 includes a terminal position lock body 98. A terminal position lock locking mechanism 100 extends from the terminal position lock body 98.

[0030] Fig. 12 is a cross-sectional view along line 12-12 in Fig. 10. As shown, the terminal position locking mechanism 100 engages in the second housing 80 to hold the second terminal position locking mechanism 96 in the second housing 80. The second housing 80 contains a terminal latch 102 that engages in the second electrical terminal 88 to hold the second electrical terminal 88 in the second housing cavity 82. The second terminal position locking mechanism 96 includes a locking reinforcement 104 located behind the terminal latch 102 to hold the terminal lock in a terminal locking position, as opposed to a terminal release position, to prevent the terminal latch 102 from releasing the second electrical terminal 88. As shown in Fig. As shown in Figure 12, a stop 103 of the second terminal position lock 96 engages in the tab 94 of the second electrical terminal 88 to hold the second electrical terminal 88 in the second terminal cavity 82.

[0031] Back to Fig.11: The illustrated second electrical connection 88 is a plug pin, and the tab 94 extends from the plug pin. Furthermore, the illustrated second electrical connection 88 includes a split contact part 90 and is configured to engage with two electrical connections located in the first electrical connector 12. However, the second electrical connection 88 can be any type of connection. The illustrated tab 94 is a first tab 94 located on a first side of the contact part 90. The second electrical connection 88 includes a second tab 94 located on a second side of the contact part 90 and extending towards the connection end of the connection cavity. The second side of the contact part 90 is opposite the first side of the contact part 90. The illustrated second electrical connector 14 includes two second electrical connections 88.However, the second electrical connector 14 can contain any number of second electrical connections 88.

[0032] The person skilled in the art recognizes that various modifications and alternatives to the described and illustrated embodiments can be developed in light of the general teaching of the disclosure, and that the various elements and features of one example described and illustrated herein can be combined with various elements and features of another example without departing from the scope of the invention. Accordingly, the examples disclosed herein were selected by the inventor(s) solely for the purpose of describing and illustrating examples of the invention and are not intended to limit the scope of the invention or its protection, which is to be fully granted by the appended claims and their equivalents.

Claims

[1] An electrical connector comprising: an inner housing that defines a connection cavity designed to receive an electrical connection; a terminal position lock attached to the inner housing for relative movement between an open position and a closed position, wherein the terminal position lock extends into the terminal cavity when it is in the closed position; an outer casing containing an outer body defining an outer casing cavity and an outer casing opening, wherein the inner casing is held within the outer casing cavity; a lever connected to the outer casing for relative movement between a pre-composited position and a composite position, where the lever defines a lever opening; and the outer housing opening is located between the connection position lock and the lever opening. [2] The electrical connector according to claim 1, wherein the outer housing opening is arranged between the connection position lock and the lever opening when the lever is in the assembled position. [3] The electrical connector according to claim 2, wherein the connection cavity defines a connection cavity axis, wherein an insertion axis extends through the outer housing opening and the lever opening when the lever is in the assembled position, and wherein the insertion axis is perpendicular to the connection cavity axis. [4] The electrical connector according to claim 1, wherein the lever is connected to the outer housing for a relative rotary movement between the pre-assembled position and the assembled position. [5] The electrical connector according to claim 1, wherein the outer housing opening and the lever opening are designed such that a tool can be inserted through them to engage the connection position locking mechanism when the lever is in the assembled position. [6] The electrical connector according to claim 1, wherein the outer housing cavity includes at a first end a fitting opening designed to receive an associated electrical connector; further comprising a cavity seal arranged in the outer housing cavity, the cavity seal being configured to engage with the associated electrical connector; and wherein the outer housing opening is arranged between the pass opening and the cavity seal. [7] The electrical connector according to claim 1, wherein the connection position lock is configured to act as a primary locking mechanism to hold the electrical connection in the connection cavity. [8] The electrical connector according to claim 1, wherein the connection position locking mechanism is cast as a single piece of the inner housing. [9] Including an electrical connector; a connector housing containing a body that defines a housing cavity, which defines a housing cavity axis; and A connector position lock attached to the connector housing for relative movement between a pre-locked position and a locked position, the connector position lock comprising a connector position lock body and a leg extending from the connector position lock body, the leg being movable relative to the connector position lock body between a holding position and a release position, and comprising a trigger engaging in the connector housing to hold the connector position lock in the pre-locked position when the leg is in the holding position, the trigger being located at a first distance from the housing cavity axis, and the connector position lock body being located at a second distance from the housing cavity axis, which is greater than the first distance. [10] The electrical connector according to claim 9, wherein the connector position lock includes a connector position lock latch which engages in the connector housing to hold the connector position lock in the pre-locked position relative to the connector housing; and wherein the connector position locking mechanism is arranged at the second distance from the housing cavity axis. [11] The electrical connector according to claim 9, wherein the leg is a first leg and the trigger is a first trigger and the connector position lock includes a second leg extending from the connector position lock body, wherein the second leg is movable relative to the connector position lock body between a holding position and a release position and includes a second trigger engaging in the connector housing to hold the connector position lock in the pre-locking position when the second leg is in the holding position, wherein the second trigger is arranged at the first distance from the housing cavity axis. [12] The electrical connector according to claim 9, further comprising a lever attached to the connector housing for a relative movement between a pre-assembled position and an assembled position, wherein the lever engages in the leg in the assembled position and moves the leg into the release position. [13] The electrical connector according to claim 9, wherein the connector position lock is movable relative to the connector housing parallel to the housing cavity axis between the pre-locked position and the locked position. [14] An electrical connector comprising: a housing that defines a connection cavity extending between a contact end and a connection end; an electrical connection arranged in the connection cavity, wherein the electrical connection includes a contact part configured to engage with an associated connection, and a connecting part configured to engage with a conductor, wherein the contact part is arranged closer to the contact end of the connection cavity than the connecting end, and the connecting part is arranged closer to the connecting end of the connection cavity than the contact end. wherein the electrical connection includes a tab on the contact part that extends towards the connecting end of the terminal cavity; and a connection position lock that is attached to the housing and engages in the tab to hold the electrical connection in the connection cavity. [15] The electrical connector according to claim 14, wherein the contact part of the electrical connection is a plug pin and the tab extends from the plug pin. [16] The electrical connector according to claim 14, wherein the tab is a first tab arranged on a first side of the contact part, and the electrical connector includes a second tab on a second side of the contact part extending towards the connection end of the connection cavity. [17] The electrical connector according to claim 16, wherein the second side of the contact part is opposite the first side of the contact part. [18] The electrical connector according to claim 14, wherein the housing includes a terminal lock which is movable between a terminal lock position and a terminal release position, wherein the terminal lock engages in the electrical terminal to hold the electrical terminal in the terminal cavity when it is in the terminal lock position. [19] The electrical connector according to claim 18, wherein the terminal position lock engages in the terminal locking mechanism to keep the terminal locking mechanism in the terminal locking position.

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