MODULAR HIGH-CURRENT CONNECTOR SYSTEM

Description

[0001] The invention is based on a modular high-current connector according to the preamble of independent claim 1.

[0002] Such high-current connectors are used for high-current applications and in particular for supplying power to transformers. State of the art

[0003] WO 2019 / 219126 A1 shows a connector for high-current applications. Two contact elements can be bridged together for higher energy transfer.

[0004] Such connectors are sized to suit their specific application. Different sizes are generally used for different applications.

[0005] DE 10 2018 127 720 B3 shows a high-current connector for installation and / or mounting in or on an electrical device. The high-current connector is an angled connector, meaning it has a cable outlet that is angled away from its mating connector area. In this case, the cable outlet consists of a separate retaining plate and a part of the counter-insulating body on the cable connection side that is angled away from the mating connector area.

[0006] WO 2019 / 219126 A1 discloses a high-current connector comprising an insulating body with at least two contact chambers, each containing a separate contact element. The contact elements can be electrically bridged via a flat metal piece that encloses the contact elements.

[0007] The German Patent and Trademark Office has searched the following prior art in the priority application for the present application: DE 10 2018 127 720 B3 and WO 2019 / 219 126 A1. Task

[0008] The object of the invention is to propose a high-current connector that can be modularly adapted to the respective area of ​​application.

[0009] The problem is solved by the subject matter of independent claim 1.

[0010] Advantageous embodiments of the invention are specified in the subclaims and the following description.

[0011] The high-current connector according to the invention comprises a first housing part and a second housing part connected thereto. The connection between the two housing parts can be realized via a screw connection.

[0012] A pin contact is located in the first housing part. The first housing part forms the plug-in area or the plug-in side of the high-current connector. The contact pin therefore forms the contacting means for a socket, for example, a transformer socket.

[0013] The second housing section contains a contact element for electrical connection to a connected electrical cable. The second housing section has an open housing wall. This open housing side can be closed with a housing cover. However, the housing wall also forms the connection point for securing another housing section.

[0014] It is preferably possible to equip the modular high-current connector with a third housing part. The third housing part is fixed to the second housing part. A screw connection is preferably used for this purpose. Similar to the second housing part, a further connection contact element is arranged in the third housing part for electrical connection to another cable to be connected.

[0015] It is possible to equip the modular high-current connector with additional housing sections, a fourth, a fifth, and / or a sixth housing section. Each of these housing sections contains a connection contact element for electrically connecting a further cable to be connected. The housing sections are arranged one behind the other and fixed to one another. The third housing section is then fixed to the second housing section, the fourth housing section is fixed to the third housing section, and so on. The last housing section in each case is closed using the aforementioned housing cover, so that the high-current connector or its housing is completely closed and media-tight. This allows the high-current connector to be expanded as required. The same components can be used for this.It is also possible to connect several housing parts using common connecting elements: two housing parts -> medium-length screws, three housing parts -> longer screws, etc.

[0016] Electrical lines are connected to each of the individual connection contact elements. Preferably, the respective connection contact elements are electrically connected to the pin contact. Higher currents can be transmitted via the pin contact via multiple lines connected in parallel. For example, the high-current connector can transmit 400A with one line, 800A with two lines, and 1200A with three lines. The high-current connector according to the invention can be expanded as required and thus adapted to various applications.

[0017] According to the invention, the connecting contact elements each have a connection area and a contact area. The electrical lines are connected to the connecting area. This is done via a crimp connection. For this purpose, the connecting area has a cylindrical opening. A crimp connection offers high vibration protection. This type of connection technology is therefore particularly popular in the railway sector. The contact area of ​​the connecting contact element has a cylindrical through-opening. To electrically contact the connecting contact elements, the pin contact is inserted into the through-openings of the connecting contact elements. The diameters of the pin contact and the individual through-openings are coordinated for this purpose.

[0018] Preferably, the opening or crimp opening and the through-hole of the respective connection contact element are aligned orthogonally to each other. This ensures that the connection direction of the cables and the plug-in direction of the high-current connector are also orthogonal to each other. The cables run flat away from the connected device, which is particularly advantageous in the railway sector, as the cables run flat against a wagon wall and can thus be laid in a space-saving manner.

[0019] In order to ensure optimal electrical contact between the connection contact element and the pin contact, a circumferential contact strip is preferably arranged within the cylindrical through-opening of the respective connection contact element.

[0020] Preferably, the pin contact is substantially cylindrical and has a connection area and a contact area. The connection area forms the above-described electrical contact between the pin contact and the connection contact elements. The contact area forms the electrical contact with a device or connection socket.

[0021] Advantageously, the contact area of ​​the pin contact has a circumferential thread. Furthermore, the contact area of ​​the pin contact preferably has a circumferential ring. The circumferential thread runs from the contact tip of the pin contact to the circumferential ring. This makes it possible to contact the pin contact with a so-called cable lug, which is pressed against the circumferential ring by a nut screwed onto the thread. This type of contact has proven to be particularly durable and extremely vibration-resistant. Therefore, this contact technology is particularly suitable for the railway sector.

[0022] The pin contact preferably has an axial opening in the contact area, which serves, for example, as a receptacle for a screwdriver or a wrench, in particular an Allen key. This allows the contact pin to be held in place while tightening the lock nut for the cable lug. A polygonal outer contour can also be designed to accommodate a wrench. However, the outer contour must be designed within the inner diameter of the thread. Example

[0023] An embodiment of the invention is illustrated in the drawings and explained in more detail below. They show: Fig. 1 is a perspective view of two high-current connectors according to the invention, Fig. 2 is a side sectional view of a high-current connector according to the invention, Fig. 3 is a sectional view of a pin contact which is in electrical contact with two connection contact elements, Fig. 4 is a perspective view of a pin contact which is in electrical contact with two connection contact elements, Fig. 5 is a sectional view of a connection contact element, Fig. 6 is an exploded view of a high-current connector according to the invention and Fig. 7 is a perspective sectional view of the first housing part of the high-current connector according to the invention.

[0024] 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.

[0025] Directional directions such as "left", "right", "top" and "bottom" are to be understood with reference to the respective figure and may vary in the individual representations compared to the object depicted.

[0026] The Figure 1 shows a perspective view of two high-current connectors 1, 1' according to the invention. In the smaller version of the high-current connector 1, one electrical line (not shown) is connected. In the larger version 1', two electrical lines are connected. The larger version of the high-current connector 1' is thus capable of transmitting a higher current. Figure 2 The sectional view of the larger high-current connector version 1' is shown. The electrical cables connected to the high-current connector 1, 1' are secured via a cable gland 6, 6'.

[0027] The high-current connector 1, 1' has a first housing part 7 in which a pin contact 9 is arranged. The pin contact 9 is in the Figures 3 and 4 can be seen in detail. The pin contact 9 has a contact area K' and a connection area A'. The contact area K' of the pin contact 9 protrudes from the first housing part 7 on the plug-in side and, when plugged in, forms the electrical contact with a device socket (not shown).

[0028] The pin contact 9 extends with its connection area A' into a second housing part 8 of the high-current connector 1, 1'. Here, the pin contact 9 is in electrically conductive contact with at least one connection contact element 5. An electrical line (not shown) is connected to each connection contact element 5 using crimping technology. The pin contact 9 and the connection contact element 5, or their main axes of symmetry, are aligned orthogonally to each other. As a result, the plugging direction and the cable connection direction of the high-current connector are also perpendicular to each other.

[0029] In Figure 6It can be seen that the second housing part 8 has an open housing wall 10. The edge of the open housing wall 10 is provided with a circumferential groove 11, into which a seal (not shown) for sealing the media of the high-current connector 1, 1' is inserted. The open housing wall 10 can be closed with a housing cover 12. For modular expansion of the high-current connector 1', a further housing part, namely a third housing part 13, can be placed on the open housing wall 10.

[0030] In Figure 2 It can be seen that the third housing part 13 is also provided with a connection contact element 5, which can be provided with a further connected line (not shown) on the connection side and is electrically contacted with the pin contact 9 on the contact side.

[0031] In Figure 5A connection contact element 5 according to the invention is shown in section. The connection contact element has a groove 16 on both sides. Webs 17 formed in the second housing part 8 engage in these grooves 16, thereby ensuring that the connection contact element is secured against rotation. The connection contact element 5 is fixed in the second housing part 8 by a fixing means 14. The same fixing element 14 can, of course, also be used for other housing parts, for example, a third housing part 13.

[0032] The connection contact element 5 has a connection area A and a contact area K. The connection area A has a cylindrical opening 2, which is provided for a crimp connection with an electrical cable to be connected. The contact area K of the connection contact element 5 has a cylindrical through-opening 3. For the electrical connection between the connection contact element 5 and the pin contact 9, the pin contact 9 is inserted into this through-opening 3. A contact strip 4 is arranged within the through-opening 3, which ensures reliable electrical contact between the connection contact element 5 and the pin contact 9.

[0033] The main axes of symmetry of the crimp opening 2 and the through-hole 3 are aligned orthogonally to each other. As a result, the plug-in direction (SR) and the cable connection direction (KA) of the high-current connector 1, 1' are aligned perpendicular to each other. The cables thus run flat away from the device, enabling easy cable routing and installation.

[0034] The contact area K' of the pin contact 9 is enclosed by a circumferential ring 15. Starting from the circumferential ring 15 and extending toward its contact tip, the contact pin 9 has a circumferential thread 20. When connecting the high-current connector 1, 1' to, for example, a transformer, a ring-shaped cable lug (not shown) is guided around the contact tip of the contact pin 9. The cable lug is fixed by at least one threaded screw (not shown), thereby pressing it against the annular surface of the circumferential ring 15. Preferably, a second threaded screw or lock nut is used here to ensure optimal vibration protection.

[0035] In Figure 7The first housing part 7 of the high-current connector 1 is shown in a perspective sectional view. The contact pin 9 is aligned such that its contact area K' protrudes from the insulating body 19 in the plug-in direction SR. The insulating body 19 runs above the circumferential ring - opposite to the plug-in direction SR - to the first housing part 7 of the high-current connector 1. The insulating body 19 protrudes from the first housing part 7 and is only held in its upper area by the first housing part 7. This freely extending part of the insulating body 19 later protrudes into a device wall or into the transformer housing.

[0036] The contact pin 9 has two circumferential grooves 20, 20' in the area extending within the insulating body 19. A sealing ring 21, 21' is inserted into each of these grooves 20, 20'. This provides a media-tight seal for the high-current connector 1 on the mating side.

[0037] The contact pin 9 protrudes—counter to the plugging direction SR—from the first housing part 7 into at least one second housing part 8 and, if necessary, also into a third housing part 13. In this area, the above-mentioned connection contact elements 5 are connected to the pin contact 9.

[0038] The contact pin 9 has a shoulder 22 in the connection direction. Via this shoulder 22, the pin contact 9 can be fixed or clamped into the first housing part 7 using a fixing means 23.

[0039] The pin contact 9 is preferably made of pure copper to ensure adequate current-carrying capacity. Pure copper means that the material has a copper content of at least 99 percent by weight. The connecting contact element(s) can also be made of such pure copper.

[0040] 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

[0041] 1High-current connector 2Opening 3Through-hole 4Contact strip 5Connecting contact element 6Cable gland 7First housing part 8Second housing part 9Pin contact 10Open housing wall 11Groove 12Housing cover 13Third housing part 14Fixing means 15Circumferential ring 16Groove 17Bridge 18Thread 19Insulating body 20Groove 21Sealing ring 22Step 23Fixing means A, A'Connection area K, K'Contact area KA, Cable connection direction SR, Plug-in direction

Claims

1. Modular high-current connector (1) which has a first housing part (7) and connected thereto a second housing part (8), wherein the high-current connector (1) has at least one connection contact element (5), disposed in the second housing part (8), for electrically connecting to a line to be connected, and a pin contact (9), in the first housing, for electrically contacting a device socket or a mating connector, wherein the connection contact elements (5) each have a connection region (A) and a contact region (K), wherein the connection region (A) has a cylindrical opening (2) and the contact region (K) has a cylindrical through-opening (3), and wherein the pin contact (9) for electrically contacting the connection contact elements (5) is introduced into the through-openings (3) of the latter, wherein the second housing part (8) has an open housing wall (10) which is able to be closed with a housing cover (12), and wherein a further housing part is able to be fixed to the open housing wall (10), a further connection contact element (5) being disposed in the further housing part.

2. Modular high-current connector (1) according to Claim 1, characterized in that the modular high-current connector (1) has a third housing part (13).

3. Modular high-current connector (1) according to the preceding claim, characterized in that the modular high-current connector (1) has further housing parts, in particular a fourth, a fifth, and a sixth housing part, and in that the further housing parts are embodied in a manner analogous to that of the third housing part (13).

4. Modular high-current connector (1) according to Claim 2 or 3, characterized in that one connection contact element (5) is in each case disposed in the second housing part (8) and / or in the third housing part (13) and / or in the fourth housing part and / or in the fifth housing part and / or in the sixth housing part.

5. Modular high-current connector (1) according to one of the preceding claims, characterized in that the opening (2) and the through-opening (3) are oriented orthogonally to each other.

6. Modular high-current connector (1) according to one of the preceding claims, characterized in that an encircling contact strip (4) is disposed within the cylindrical through-opening (3).

7. Modular high-current connector (1) according to one of the preceding claims, characterized in that the pin contact (9) is configured so as to be substantially cylindrical, and has a connection region (A') and a contact region (K').

8. Modular high-current connector (1) according to the preceding claim, characterized in that the contact region (K') of the pin contact (9) has an encircling ring (15).

9. Modular high-current connector (1) according to one of the two preceding claims, characterized in that the contact region (K') of the pin contact (9) has an encircling thread.

10. Modular high-current connector (1) according to the two preceding claims, characterized in that the encircling thread runs from the contact tip to the encircling ring (15).

11. Modular high-current connector (1) according to one of the four preceding claims, characterized in that the pin contact (9) in the contact region has an axial opening.

12. Modular high-current connector (1) according to one of the four preceding claims, characterized in that the first housing part (7) and the second housing part (8) connected thereto are integrally embodied.