Modular connector module for a heavy-duty industrial connector

Description

[0001] The invention is based on a connector module for a heavy-duty industrial connector according to the preamble of independent claim 1. The invention further relates to a method for producing such a connector module according to independent claim 6.

[0002] Such connector modules are required as part of a modular connector system to flexibly adapt a connector, especially a heavy-duty industrial connector, to specific requirements regarding signal and power transmission, e.g., between two electrical devices. Typically, connector modules are inserted into corresponding holding frames, sometimes also referred to as articulated frames, module frames, or modular frames. The holding frames thus serve to accommodate several similar and / or different connector modules and securely attach them to a surface and / or a device wall and / or in a connector housing or similar. State of the art

[0003] The connector modules typically each have a substantially cuboid-shaped insulating body or housing. These insulating bodies or housings can serve, for example, as contact carriers, accommodating and securing contacts of various types. The function of a connector formed in this way is therefore very flexible. For example, pneumatic modules, optical modules, modules for transmitting electrical energy and / or electrical analog and / or digital signals can be accommodated in the respective insulating body or housing and thus be used in the modular connector system. Connector modules are increasingly also performing measurement and data technology tasks.

[0004] Ideally, holding frames are used which are formed from two frame halves which are connected to one another in an articulated manner. The connector modules are provided with approximately rectangular holding means protruding from the narrow sides. Recesses or openings in the form of openings closed on all sides are provided in the side parts of the frame halves, into which openings the holding means insert when the connector modules are inserted into the holding frame. So-called articulated frames are used most frequently. To insert the connector modules, the holding frame is unfolded, i.e. opened, with the frame halves being unfolded around the joints only far enough for the connector modules to be inserted. The frame halves are then clipped together, i.e. the holding frame is closed, with the holding means moving into the recesses and ensuring a secure, positive fit for the connector modules in the holding frame.

[0005] The modular industrial connectors described above offer a high degree of flexibility and can be configured for a wide variety of applications by assembling connector modules with different functions together in a common mounting frame. However, the number of connector module slots in a mounting frame is limited. This limits the flexibility of such an industrial connector.

[0006] Ideas to increase the flexibility of such an industrial connector with connector modules, which in turn are modularly composed of various functional units, run counter to customer wishes, namely to have less effort in the assembly of an industrial connector.

[0007] The German Patent and Trademark Office searched the following prior art in the priority application for the present application: DE 10 2017 123 331 B3, DE 10 2014 108 847 A1 and DE 10 2018 115 371 A1.

[0008] US 2006 / 030222 A1 shows an audio jack formed from several jack units that are coupled together via a connecting element according to the dovetail principle.

[0009] US 2006 / 110978 A1 shows a modular power connector formed from several insulating blocks that are assembled with a connector according to the dovetail principle.

[0010] FR 2 496 192 A1 shows a connector array which consists of alternating terminal blocks and contact carrier blocks which fit together. Task

[0011] The object of the invention is to provide a connector module which enables a modular industrial connector with increased modularity without at the same time increasing the assembly effort for such a connector.

[0012] The problem is solved by the subject matter of the independent claim and by the method according to the invention.

[0013] Advantageous embodiments of the invention are specified in the respective subclaims and the following description. Disclosure of the invention

[0014] The connector module according to the invention is intended for use in a modular industrial connector. Typically, several similar and / or different connector modules are installed in a so-called retaining frame. The retaining frame is then installed in a connector housing or a device panel. The connector module according to the invention is formed from at least two independent functional units.

[0015] A functional unit forms an independent component. This means that the functional unit can function independently, i.e., without another functional unit connected to it. A functional unit does not become technically usable until two or more functional units are combined to form a connector module.

[0016] A functional unit preferably has at least one contact element and / or a sensor and / or an edge computer. The edge computer can, for example, collect, store, process and send data. The contact element can, for example, be an electrical contact element for power or signal transmission. The contact element can also be an optical contact element to which, for example, an optical fiber is connected. A functional unit can have several contact elements, in particular several different contact elements. For example, electrical and optical contact elements can be mixed with one another. The sensor can, for example, be a current sensor that monitors an adjacent contact element, for example arranged in an adjacent functional unit.However, temperature sensors, optical sensors, in particular scattered light sensors, or other sensors may also be provided. A functional unit may also contain multiple sensors, in particular different sensors. A functional unit may also contain one or more sensors and simultaneously one or more contact elements.

[0017] The functional units of a connector module can operate completely independently of one another. However, the functional units can also experience a synergistic effect when combined, especially when sensors from one functional unit are combined with contact elements from another.

[0018] When assembled, the functional units enclose a cavity. A cavity here refers to a hollow space that is accessible from the outside. For this purpose, each functional unit has a bulge that forms the aforementioned hollow space or cavity when the functional units are assembled.

[0019] The cavity can also have two openings to the outside. This allows, for example, a separate fixation agent to be introduced on both sides.

[0020] The cavity can extend essentially in the mating direction and / or perpendicular to the mating direction of the connector module. The mating direction is the direction in which the connector module is guided to a mating connector module during the mating process. By aligning the cavity in this way, it can be easily filled with a fixing agent, or the fixing agent can be easily inserted into the cavity.

[0021] By at least partially filling the cavity with the fixation agent, the functional units are fixed together. The fixation agent is, in particular, a separate component. The fixation of the functional units to one another can be reversible if the fixation agent is designed such that it can be removed from the cavity. In this case, the functional units can be reused and combined differently. For example, a defective functional unit can be replaced without having to dispose of the still functioning functional unit previously combined with it. Such a solution is particularly sustainable.

[0022] The fixation device can be a separate, existing component. The fixation device takes the form of a component extruded into the space. Such a component can be easily produced, for example, using an injection molding process.

[0023] However, the fixative can also be created during an injection molding process. In this process, the functional units are first brought together. The resulting cavity is filled with a plastic material in a plastic injection molding process, which cures, creating or forming the fixative. Partially filling the cavity may be sufficient.

[0024] The initially liquid fixative can be injected into one access opening of the cavity, and any excess material can then escape through the second opening. Having two openings would also accelerate the curing process accordingly.

[0025] Preferably, the fixing means has a cross-shaped cross-section. Two of the crossbeams can each be anchored in a functional unit, creating a particularly stable and backlash-free connection between the functional units. The absence of backlash in the connection between the functional units is particularly important. Excessive play between the functional units leads to a "wobbly" connector module and ultimately reduces the functionality of an industrial connector equipped with it.

[0026] Advantageously, the functional units each have a complementary offset on their joined side. This allows the functional units to be joined together with a positive fit. The offset ensures that the functional units are held together in or against the mating direction, even without fixing devices. This gives the connector module greater stability, especially during the mating process.

[0027] The manufacturing process of a connector module according to the invention is described below. The process steps mentioned can be permuted as needed.

[0028] First, at least two independent functional units are assembled or combined. In the assembled state, the functional units enclose a cavity.

[0029] The cavity is then at least partially filled with a fixative, which secures the functional units together. A pre-prepared fixative can be inserted or pushed into the cavity. Alternatively, the cavity can be filled with a hardening compound, for example, in an injection molding process. The hardened compound then forms the fixative.

[0030] In a particularly advantageous embodiment of the invention, retaining means for securing the connector module in a holding frame are molded onto the narrow sides of the connector module, or portions thereof are finished. This process step can be performed before, after, or during the cavity filling with the retaining means.

[0031] As is well known, connector modules have differently sized retaining elements on their narrow sides. This ensures polarization (correct insertion in the intended orientation) of the connector modules in the retaining frame, which has matching recesses of varying sizes. The aforementioned subsequent molding of the retaining elements allows for even more flexible combinations of functional units, since the polarization direction does not need to be considered in advance. Example

[0032] An embodiment of the invention is illustrated in the drawings and explained in more detail below. They show: Fig. 1 shows a perspective and partially transparent view of a first embodiment of a connector module according to the invention; Fig. 2 shows a perspective view of a fixing means; Fig. 3 shows a perspective view of a second embodiment of a connector module according to the invention; Fig. 4 shows a perspective and partially transparent view of a third embodiment of a connector module according to the invention; Fig. 5 shows a perspective section of a connector module according to the invention.

[0033] The figures contain partially simplified, schematic representations. In some cases, identical reference symbols are used for identical, but possibly not identical, elements. Different views of identical elements may be scaled differently.

[0034] The Figure 1 shows a perspective and partially transparent representation of a first embodiment of a connector module 1 according to the invention.

[0035] The connector module 1 consists of two functionally independent functional units 2, 2'. On the narrow sides of the connector module 1 formed by the functional units 2, 2', the functional units 2, 2' each have differently sized holding means 3, 3' with which the connector module 1 is fastened in a holding frame (not shown) of an industrial connector (not shown). The functional units 2, 2' have openings 4 into which (different) contact elements 5 can be inserted. However, other elements, such as sensors, can also be provided in the functional units 2, 2'. Since the related functionality of the functional units 2, 2' plays no role for the present invention, this will not be discussed in detail below. The connector modules 1 are plugged together in the plugging direction SR with a corresponding mating connector module (not shown).

[0036] The combined functional units 2, 2' enclose a cavity 6. The cavity 6 is filled with a fixing agent 7, which is Figure 2 is shown separately. The fixing means 7 has the shape of a cross extruded into the space.

[0037] In the first embodiment of the connector module ( Figure 1 ), the functional units 2, 2' form a transverse division of the connector module 1. The functional units 2, 2' are brought together with their designated narrow sides. The fixing means 7 is then pushed or injected axially, i.e., in the plugging direction SR, into the connector module 1 in order to reconnect the functional units 2, 2' to one another, ideally in a detachable manner.

[0038] The functional units 2, 2' each have offsets 9 aligned complementarily to each other on their joined sides. As a result, the functional units 2, 2' do not shift axially relative to each other, even if no fixing means 7 is yet present. Thus, the functional units 2, 2' are stabilized during the subsequent manufacturing process, for example, in an injection mold.

[0039] In Figure 3a second embodiment of a connector module 1' according to the invention is shown. In this embodiment, the connector module 1' is split lengthwise. Therefore, the fixing means 7 is pushed or injected into the narrow side of the connector module 1' perpendicular to the plugging direction SR. Connector modules 2, 2' split lengthwise in this way have the disadvantage that the diameter of the contact elements that can be accommodated therein is limited. This also often gives rise to problems with the air and creepage distances. However, one advantage of the longitudinal division of the connector modules is that the functional units can be fastened in a holding frame on their own, i.e. without being connected to another functional unit, if the slots in the holding frame are provided accordingly.

[0040] A third embodiment of a connector module 1" according to the invention is shown in Figure 4This variant again involves a previously mentioned transverse division of the connector module 1" by the functional units 2, 2' joined together on the narrow side. In this exemplary embodiment, the fixing means 7 extends within the connector module 1" both in the plug-in direction SR and perpendicular to it. The cavity 6 is of course designed accordingly. This design of the fixing means 7 ensures particularly stable and play-free fixing of the functional units 2, 2' to one another. Of course, no finished component can be used as the fixing means 7 for this purpose. In this exemplary embodiment, the fixing means 7 is injected into the cavity 6 in the form of hardening material.

[0041] In Figure 5a section of a connector module 1, 1', 1" according to the invention can be seen. The section focuses on a holding means 3' formed on the respective narrow sides of the connector module 1, 1', 1". The holding means 3' can (optionally) be designed in the exemplary embodiments shown, for example, according to the illustration in Fig. 5be designed as follows. The holding means 3' consists of a base 3a formed on the functional unit 2, 2', which base has a groove 8. The base 3a essentially corresponds to the small holding means 3 of the connector module 1, 1', 1" and fits accordingly into the narrower recess of the aforementioned holding frame. In an injection molding process, an enlargement 3b is injection-molded onto the base 3a. The base 3a plus the enlargement 3b corresponds to the larger holding means 3' of the connector module 1, 1', 1" and fits accordingly into the larger recess of the aforementioned holding frame. In this embodiment, the functional units can be permuted with one another as desired, since they are only provided with the appropriate polarization for the holding frame afterwards, in the aforementioned injection molding process.

[0042] Although various aspects or features of the invention are shown in combination in the figures, it will be apparent to those skilled in the art—unless otherwise stated—that the illustrated and discussed combinations are not the only possible ones. In particular, corresponding units or feature complexes from different embodiments can be interchanged. List of reference symbols

[0043] 1Connector module 2Functional unit 3Holding means 3aBase 3bEnlargement 4Opening 5Contact element 6Cavity 7Fixing means 8Groove 9Offset SRS plug direction

Claims

1. Connector module (1, 1', 1") for a modular industrial connector, wherein the connector module (1, 1', 1'') is formed from at least two independent functional units (2, 2'), wherein the functional units (2, 2') form a cavity (6) with each other when in the assembled state, characterized in that the cavity (6) extends in the mating direction (SR) and perpendicularly to the mating direction (SR) of the connector module (1, 1', 1'') and the functional units (2, 2') can be fixed to one another by a fixing means (7), in the form of curing material, being injected into the cavity (6) and the fixing means (7) at least partially filling the cavity (6) to fix the at least two functional units (2, 2') to one another.

2. Connector module according to Claim 1, characterized in that the fixing means (7) is a component extruded into the space.

3. Connector module according to one of the two preceding claims, characterized in that the fixing means (7) has a cross-shaped cross-section.

4. Connector module according to one of the preceding claims, characterized in that the functional units (2, 2') each have an offset (9) on their sides which are brought together, wherein the offsets (9) are oriented in a manner complementary to each other.

5. Method for producing a connector module (1, 1', 1") for a modular industrial connector according to Claim 1, comprising the following method steps: - wherein at least two independent functional units (2, 2') are first assembled, wherein the functional units (2, 2') enclose a cavity (6) with each other when in the assembled state, - wherein the cavity (6) is then at least partially filled with a fixing means (7), whereby the functional units (2, 2') are fixed to each other, - wherein the cavity (6) is filled with the fixing means (7) by at least partially filling a fixing means (7) the cavity (6) with a curing compound.

6. Method for producing a connector module (1, 1', 1'') for a modular industrial connector according to the preceding claim, characterized in that holding means (3) are integrally formed on the narrow sides of the connector module (1, 1', 1") to fix the connector module (1, 1', 1'') in a holding frame.