CONTACT ASSEMBLY FOR AN ELECTRICAL CONNECTOR AND METHOD FOR MANUFACTURING AN ELECTRICAL CONNECTOR

Description

[0001] The invention relates to a contact assembly for an electrical connector, comprising a sleeve-shaped contact element made of a metallic, first material, according to the preamble of claim 1.

[0002] The invention further relates to an electrical connector, in particular a high-voltage connector, and an electrical connection consisting of said connector and a corresponding electrical mating connector.

[0003] The invention also relates to a method for manufacturing an electrical connector.

[0004] Various electrical connectors are known from electrical engineering. Electrical connectors are known to transmit electrical supply signals and / or data signals to corresponding mating electrical connectors. A connector or mating connector can be, for example, a plug, a panel-mount connector, a socket, a coupling, or an adapter. The terms "connector" and "mother connector" used within the scope of the invention are representative of all variants.

[0005] Electrical connectors are subject to particularly stringent requirements, especially in high-voltage applications. High-voltage connectors are used in automotive engineering, primarily in electric and / or hybrid vehicles, to supply charging current to a vehicle battery, to extract stored energy from the battery and supply it to the electric drive, or to connect multiple batteries or battery modules. The electrical connection must reliably and permanently prevent the ingress of moisture and contaminants and ensure the flawless transmission of high currents. Furthermore, the connector, particularly a high-voltage connector or one used to transmit safety-relevant control signals, should be mechanically robust and reliably secured against unintentional opening.

[0006] Electrical connectors, especially those used in automotive engineering, often need to be manufactured cost-effectively in mass production. For this reason, connector contact elements, particularly outer conductor contact elements, are preferably manufactured using a die-casting process.

[0007] However, it has been shown that contact elements produced in this way can lose their shape or be plastically deformed at high temperatures, such as those that can occur during power transmission in high-voltage technology.

[0008] This is particularly problematic when the connection between the connector and the mating connector relies on a frictional fit, as is the case with an interference fit between the external conductor contact elements. Especially in this case, high temperatures can lead to a deterioration of the electrical and / or mechanical contact in the connector.

[0009] Regarding the technological background, reference should be made here to US 5,403,199 A, which relates to radially spring-loaded connector terminals and in particular to such a terminal for use in various high-current applications.

[0010] In view of the prior art, the object of the present invention is to provide a contact assembly that can be manufactured economically in mass production and yet has high temperature stability, and which is therefore preferably suitable for use in a high-voltage connector.

[0011] The present invention also aims to provide an electrical connector that can be manufactured economically in mass production and yet has high temperature stability, and is therefore preferably suitable for use as a high-voltage connector.

[0012] Finally, it is also an object of the invention to provide an electrical connector that can be manufactured economically in the context of mass production and that nevertheless has high temperature stability, and which is therefore preferably suitable for use as a high-voltage connector.

[0013] Furthermore, the invention aims to provide an economical method for manufacturing an electrical connector with high temperature stability.

[0014] The problem is solved for the contact assembly by the features listed in claim 1. With regard to the electrical connector, the problem is solved by the features of claim 11, and with regard to the electrical plug connection by claim 12. For the method, the problem is solved by claim 14.

[0015] The dependent claims and the features described below relate to advantageous embodiments and variants of the invention.

[0016] A contact assembly for an electrical connector is provided, comprising a contact element made of a metallic material that is at least partially sleeve-shaped. The contact element has a first cladding surface for electrical and mechanical contact with a mating contact element of an electrical connector and a second cladding surface distinct from the first.

[0017] The electrical connector is preferably a high-voltage connector suitable for transmitting high electrical currents. The contact assembly, and in particular the contact element of the contact assembly, is therefore preferably designed to be suitable for electrical power transmission in high-voltage technology, i.e., for transmitting high electrical currents (for example, 100 A to 700 A) at AC voltages of 30 V to 1 kV or more, or DC voltages of 60 V to 2 kV or more, particularly in automotive engineering.

[0018] The contact assembly can also be advantageous for connectors for power and / or data transmission with only low electrical currents.

[0019] A sleeve-shaped contact element can be understood to be, in particular, a ring- or tubular-shaped contact element (preferably an elongated contact element) with a round cross-section, but possibly also an elliptical, rectangular or other cross-section.

[0020] The sleeve-shaped contact element does not have to be completely closed and can therefore, for example, only be partially ring-shaped and / or may have recesses, in particular axial slots.

[0021] The sleeve-shaped contact element does not need to be sleeve-shaped or hollow along its entire length. For example, the sleeve-shaped contact element can also have a sleeve-shaped contact area only in a front end section intended for contact with the mating contact element, in order to be connectable to pin-shaped mating contact elements of the mating connector.

[0022] As described below, the sleeve-shaped contact element of the contact assembly can preferably be designed as an outer conductor contact element of the connector. However, the sleeve-shaped contact element can also be designed as an inner conductor contact element of the connector.

[0023] Preferably, the second lateral surface is a lateral surface facing away from the first lateral surface.

[0024] The first lateral surface and / or the second lateral surface can each be a completely contiguous surface, but may also each be composed of several individual surfaces, especially if the contact element is slotted or has recesses extending through the respective lateral surface.

[0025] In principle, the first material can be any metallic material, but preferably a zinc material or an aluminum material, or at least an alloy comprising zinc and / or aluminum, is provided.

[0026] According to the invention, the contact assembly comprises a limiting element. The limiting element is preferably made of a second material different from the first. It is provided that the limiting element has a higher heat resistance than the contact element (in particular, it may be provided that the second material has a higher heat resistance than the first material). The limiting element is attached at least partially (but preferably over its entire surface) to the second lateral surface of the contact element.

[0027] Hot strength is a well-known characteristic that describes the strength of a material at elevated temperatures. A material or object with high hot strength is therefore less prone to deformation at a defined temperature than a material or object with lower hot strength.

[0028] In a particularly preferred embodiment of the invention, it can be provided that the second material has a smaller coefficient of thermal expansion than the first material.

[0029] The coefficient of thermal expansion (also known as the "thermal expansion coefficient" or simply "expansion coefficient") is a characteristic value that describes the behavior of a material with respect to changes in its dimensions due to thermal expansion caused by temperature changes. The coefficient of thermal expansion can be expressed as the coefficient of linear thermal expansion (also known as the "linear thermal expansion coefficient"), the coefficient of surface thermal expansion (also known as the "area thermal expansion coefficient"), or the coefficient of volumetric thermal expansion (also known as the "spatial thermal expansion coefficient").

[0030] Preferably, the coefficient of thermal expansion of the second material is smaller than 20 10 6 K , especially preferably smaller than 15 10 6 K , especially preferably smaller than 13 10 6 K , even more preferably smaller than 12 10 6 K .

[0031] The limiting element can also be referred to as a support element, stabilizing element, or reinforcing element. The limiting element advantageously mechanically restricts thermal deformation of the contact element, in particular movement of the contact element caused by a thermal process, such as thermal expansion or thermal creep.

[0032] The limiting element can therefore advantageously serve to stabilize the contact element. The separate support structure provided by the limiting element makes the contact element particularly suitable for use at high operating temperatures, for example, due to high current transmission, thus enabling the contact assembly to exhibit better dimensional stability at high temperatures than the contact element alone. The limiting element can therefore prevent deformation of the contact element—especially deformation in the radial direction with respect to the central or longitudinal axis of the contact assembly or connector—and thus prevent the contact element from separating from the corresponding mating contact element.

[0033] An electrical connector equipped with the proposed contact assembly is particularly advantageous for transmitting high currents or safety-relevant signals, since even under adverse environmental conditions, such as high temperatures or high pressure, it can be reliably ensured that the electrical and / or mechanical connection with the mating connector does not deteriorate.

[0034] Because the limiting element has a higher heat resistance than the contact element, the contact assembly as a whole has improved heat resistance compared to the contact element.

[0035] At the same time, the proposed contact assembly is particularly easy and cost-effective to manufacture, since the contact element can still be produced, for example, using die-casting technology and then reinforced with a simple limiting element requiring only a small amount of material.

[0036] In a further development of the invention, it can be provided that the first lateral surface is an inner surface of the contact element, and the second lateral surface is an outer surface of the contact element facing away from the inner surface.

[0037] The contact element can thus be internally contacted by the corresponding mating contact element of the mating connector by inserting the mating contact element into the contact element. An outer surface of the mating contact element can therefore establish mechanical and electrical contact with the first surface of the contact element, preferably across its entire surface, but optionally only in sections.

[0038] Preferably, the sleeve-shaped contact element in this case is designed to also contain further components of the connector, for example a dielectric or an insulator and optionally further contact assemblies or contact elements, such as one or more inner conductor contact elements.

[0039] The limiting element can be applied to the outside of the contact element, preferably over its entire surface, but optionally only in sections, and thus advantageously block temperature-induced expansion of the contact element, thereby preventing a loss of contact with the mating contact element on the inside. The limiting element can be designed in the form of a cage sleeve to prevent the contact element from moving radially outwards away from the mating contact element as the temperature rises.

[0040] In an advantageous embodiment of the invention, it can be provided in particular that the first lateral surface is an outer surface of the contact element, and the second lateral surface is an inner surface of the contact element facing away from the outer surface.

[0041] The contact element can thus be externally contacted by the corresponding mating contact element of the mating connector by placing the mating contact element onto the contact element or by inserting the contact element into the mating contact element. The mating contact element can therefore preferably be sleeve-shaped. An inner surface of the mating contact element can thus establish mechanical and electrical contact with the first surface of the contact element, preferably over the entire area, but optionally only in sections.

[0042] In this case, the limiting element can be incorporated into the contact element, preferably over its entire surface, but optionally only in sections, and thus advantageously block temperature-induced expansion of the contact element, thereby preventing a loss of contact with the mating contact element on the outside. The limiting element can be designed in the form of a support sleeve to prevent the contact element from moving radially inwards away from the mating contact element as the temperature rises.

[0043] Finally, it can be advantageously provided that the contact element is arranged between the limiting element and the mating contact element when the connector is connected to the mating connector.

[0044] Optionally, multiple limiting elements can be provided per contact assembly.

[0045] In principle, the limiting element can be designed in any way. For example, the limiting element can support the contact element, starting from a surrounding structure (such as a connector housing), essentially at specific points or in sections, in the form of ribs, fins, or pins. For instance, the surface of the limiting element facing the second lateral surface of the contact element can be structured.

[0046] According to a preferred embodiment of the invention, it may be particularly the case that the limiting element is sleeve-shaped or at least partially ring-shaped.

[0047] In particular, a sleeve-shaped limiting element is able to protect the contact element very effectively against unwanted thermal expansion.

[0048] A sleeve-shaped limiting element can be understood to be, in particular, a ring- or tubular limiting element with a round cross-section, but optionally also with an elliptical, rectangular, or other cross-section. The sleeve-shaped limiting element need not be completely closed and can therefore, for example, only be partially ring-shaped and / or may have recesses, in particular axial slots.

[0049] As mentioned above, multiple limiting elements may be provided, for example, two, three, four, or even more. If multiple limiting elements are provided, they may be arranged axially offset, or in particular, axially spaced, along a common contact element. An additional limiting element, which is at least partially attached to the first lateral surface of the contact element, may also be provided. However, one limiting element is usually sufficient.

[0050] In principle, the second material of the limiting element can be any material, for example a metal, a plastic, a ceramic or a combination of different materials.

[0051] According to a further development of the invention, it can be provided in particular that the second material of the limiting element is a metallic material.

[0052] Preferably, the second material can be an iron alloy, a steel alloy, or a brass alloy. However, other materials, in particular other metals mentioned above, can also be used to form the second material.

[0053] In a further development of the invention, it can be provided that the limiting element extends in a ring-shaped circumferential manner along the second lateral surface of the contact element.

[0054] Preferably, the limiting element rests on the second lateral surface at least partially, in particular completely or over the entire surface.

[0055] In a further development of the invention, it can be provided that the limiting element is force-fitted to the second lateral surface of the contact element.

[0056] The limiting element can be attached to the contact element, in particular by means of a press fit, preferably directly, but optionally also only indirectly (e.g. by arranging another element between the contact element and the limiting element).

[0057] In an advantageous embodiment of the invention, it can also be provided that the limiting element is attached to the second lateral surface of the contact element via a threaded connection formed between the limiting element and the second lateral surface of the contact element.

[0058] In principle, any connection technique can be suitable for directly or indirectly connecting the limiting element and the contact element. A snap-fit ​​connection between the limiting element and the contact element can also be used, for example, to attach the limiting element to the second lateral surface.

[0059] In a further development of the invention, it can be provided that the limiting element is attached to an axial end section of the contact element provided for connection with the counter-contact element.

[0060] The support of the contact element is particularly advantageous, or especially effective, in the area where the contact element is to be connected to the mating contact element. However, an axial offset of the limiting element relative to the contact position between the contact element and the mating contact element can also be provided, for example, due to design constraints.

[0061] Particularly preferably, the limiting element extends from the axial end section, particularly preferably from the axial end of the contact element, towards the end of the contact element facing away from the counter-contact element.

[0062] In an advantageous embodiment of the invention, it can be provided that the contact element has a first axial stop (in particular a step or a rib) for the limiting element, which is directly adjacent to the second lateral surface.

[0063] A stop for the limiting element can be particularly advantageous to prevent axial slippage of the limiting element under adverse environmental conditions and to simplify the mounting of the limiting element on the contact element.

[0064] The invention also relates to an electrical connector, in particular a high-voltage connector, comprising at least one contact assembly according to the preceding and following embodiments.

[0065] The proposed electrical connector can reliably maintain an electrical and mechanical connection even under adverse environmental conditions, particularly at the high temperatures encountered during high current transmission. Specifically, the required holding force, low electrical resistance, and high and consistent electromagnetic compatibility can be guaranteed even at temperatures exceeding, for example, 140 °C.

[0066] The proposed connector is therefore particularly well-suited as a high-voltage connector, especially for use in electromobility. For example, the electrical connector can advantageously provide a cell module connector interface for connecting battery cell modules, with particularly high temperature resistance of the contact.

[0067] The term "high voltage" in this context refers specifically to systems for automotive engineering. High-voltage transmission within the meaning of this invention can refer in particular to alternating voltages above 30 V up to 1 kV or more, or to direct voltages above 60 V up to 2.0 kV or more. Preferably, the contact element and / or the mating contact element is designed to transmit high electrical currents (e.g., up to 100 A, up to 200 A, up to 300 A, up to 400 A, up to 500 A, up to 600 A, up to 700 A, up to 1,500 A, up to 2,000 A or more) at preferably high electrical voltages (e.g., up to 500 V, up to 600 V, up to 700 V, up to 800 V, up to 900 V, up to 1,000 V, up to 1,100 V, up to 1,500 V, up to 2,000 V or more).

[0068] In principle, however, the invention can be suitable for the transmission of any supply and / or communication signals, for example also for use in high-frequency technology.

[0069] In an advantageous embodiment of the invention, at least one of the contact elements enhanced by a limiting element may be designed as an outer conductor contact element of the connector. However, an outer conductor contact element is not strictly necessary – the connector may, for example, also have only one or more inner conductor contact elements.

[0070] It may therefore also be provided that at least one of the contact elements enhanced by a limiting element is designed as an inner conductor contact element, whereby depending on the connector several such inner conductor contact elements may also be provided, for example two, three, four, five or even more inner conductor contact elements.

[0071] In particular, it can also be provided that all contact elements of the connector are equipped with a limiting element according to the invention.

[0072] The invention also relates to an electrical connector comprising an electrical connector according to the preceding and following embodiments, and the corresponding electrical mating connector.

[0073] According to the invention, a force-fit connection between the connector and the mating connector can be maintained even at high temperatures (e.g., temperatures > 85 °C). The proposed electrical connector can provide high residual holding force and low contact resistance even at high temperatures and / or reliably withstand high mechanical loads even at high temperatures.

[0074] The connector and contact assembly according to the invention can be used particularly advantageously within a vehicle, especially a motor vehicle. The term "vehicle" here describes any means of transportation, in particular vehicles on land, water, or in the air, including spacecraft. Possible areas of application are, in particular, high-voltage connectors, especially in electric and / or hybrid vehicles. However, the connector and contact assembly according to the invention are suitable for any application within the entire field of electrical engineering and are not limited to use in automotive engineering or high-voltage technology.

[0075] It should be mentioned here that the mating electrical connector may also have one or more contact assemblies according to the preceding and following descriptions. The invention therefore also relates to a mating electrical connector (in particular a high-voltage connector) for connection with a corresponding electrical connector, wherein the mating connector has at least one contact assembly according to the preceding and following descriptions.

[0076] Reinforcing at least one contact element of the mating connector, in addition to reinforcing at least one contact element of the connector itself, can further improve the temperature resistance of the connection. However, reinforcing both the contact elements of the connector and those of the mating connector is not strictly necessary. In most cases, it is sufficient to equip only the connector or the mating connector with one or more of the described contact assemblies.

[0077] In an advantageous embodiment of the invention, it can be provided that the contact element of the electrical connector is force-fitted to the mating contact element of the mating electrical connector in the connected state of the electrical plug connection.

[0078] Preferably, the mechanical connection between connector and mating connector can be provided by means of a press fit between at least one of the contact elements and one of the mating contact elements.

[0079] Although a press fit may be particularly preferred for connecting the plug connector, other connection techniques can also be provided (alternatively or additionally), for example, screwing the plug connector to the mating connector and / or a snap-fit ​​connection. The present invention is generally advantageous in combination with all common connection techniques between a plug connector and a mating connector.

[0080] The invention also relates to a method for manufacturing an electrical connector, comprising at least the following method steps: Providing a sleeve-shaped contact element made of a metallic, first material, which has a first lateral surface for electrical and mechanical contacting of a mating contact element of an electrical mating connector and a second lateral surface different from the first lateral surface; providing a limiting element, preferably made of a second material different from the first material, wherein the limiting element has a higher heat resistance than the contact element; and attaching the limiting element at least partially to the second lateral surface of the contact element.

[0081] By using the additional limiting element, whose starting material preferably has a high temperature resistance, in particular a higher temperature resistance than the starting material of the contact element, pressure- and temperature-dependent deformation of the contact element can be prevented or at least sufficiently suppressed, which is why the contacting of the contact element with the counter-contact element remains stable and functional in the long term.

[0082] By supporting the contact element from the outside and / or from the inside (depending on the arrangement of the components), a durable press fit or other connection can be created between a contact element of a connector and a mating contact element of a corresponding mating connector. Even if the first material loses stability at high temperatures, the limiting element prevents the contact element from deforming plastically to such an extent that the connector loses its mechanical and / or electrical contact.

[0083] In a further development of the invention, it can be provided that the contact element is manufactured by a die-casting process, preferably from zinc, aluminium or from an alloy comprising zinc and / or aluminium.

[0084] In this advantageous way, the cost-effective and flexible formability of the contact element can be exploited through a die-casting process and combined with the high temperature stability provided by the separate limiting element.

[0085] Preferably, the limiting element is made of a metallic material, in particular iron, steel or brass.

[0086] Features described in connection with one of the objects of the invention, namely the contact assembly, the electrical connector, the electrical plug connection, the mating electrical connector, and the method, can also be advantageously implemented for the other objects of the invention. Likewise, advantages mentioned in connection with one of the objects of the invention can also be understood as relating to the other objects of the invention.

[0087] It should also be noted that terms such as "comprising," "having," or "with" do not exclude other features or steps. Furthermore, terms such as "a" or "the," which indicate a singular number of steps or features, do not exclude a plurality of features or steps—and vice versa.

[0088] In a purist embodiment of the invention, however, it may also be provided that the features introduced in the invention with the terms "comprising," "comprising," or "with" are exhaustively listed. Accordingly, one or more lists of features within the scope of the invention may be considered complete, for example, for each claim. The invention may, for instance, consist exclusively of the features mentioned in claim 1.

[0089] It should be noted that designations such as "first" or "second" etc. are primarily used for the purpose of distinguishing between the respective device or process features and are not necessarily intended to indicate that features are mutually dependent or related to each other.

[0090] Furthermore, it should be emphasized that the values ​​and parameters described herein include deviations or fluctuations of ±10% or less, preferably ±5% or less, more preferably ±1% or less, and most preferably ±0.1% or less of the respective specified value or parameter, provided that these deviations are not excluded in the practical implementation of the invention. The specification of ranges by initial and final values ​​also includes all those values ​​and fractions enclosed by the respective specified range, in particular the initial and final values ​​and a respective mean value.

[0091] The invention also relates to a contact assembly for a connector, independent of claim 1, comprising a contact element, wherein the contact element has a first lateral surface at least for mechanically contacting a mating contact element of a mating connector and a second lateral surface distinct from the first lateral surface, and wherein the contact assembly further comprises a separate limiting element, wherein the limiting element is attached at least partially to the second lateral surface of the contact element, and wherein the contact assembly preferably has a higher heat resistance than the contact element without the limiting element. The further features of claim 1 and the dependent claims, as well as the features described in the present description, relate to advantageous embodiments and variants of this contact assembly.

[0092] Exemplary embodiments of the invention are described in more detail below with reference to the drawings.

[0093] The figures each show preferred embodiments in which individual features of the present invention are illustrated in combination with one another. Features of one embodiment can also be implemented independently of the other features of the same embodiment and can therefore be readily combined by a person skilled in the art to form further useful combinations and subcombinations with features of other embodiments.

[0094] In the figures, functionally identical elements are provided with the same reference symbols.

[0095] They show schematically: Figure 1 shows an electrical connector consisting of an electrical connector and a corresponding mating connector in a perspective, cutaway view, according to a first embodiment of the invention, wherein the connector has several contact assemblies according to the invention; Figure 2 shows an electrical connector consisting of an electrical connector and a corresponding mating connector in a perspective, cutaway view, according to a second embodiment of the invention, wherein the connector has several contact assemblies according to the invention; Figure 3 shows an electrical connector consisting of an electrical connector and a corresponding mating connector in a cutaway side view, according to a third embodiment of the invention, wherein the connector has exactly one contact assembly according to the invention;and Figure 4, a method according to the invention for manufacturing an electrical connector.

[0096] Figure 1 Figure 1 shows a perspective sectional view of an electrical connector 1 comprising an electrical plug 2 and a mating electrical plug 3. Preferably, it is a high-voltage connector for transmitting high electrical currents, particularly in automotive engineering. However, the electrical connector 1 can also be suitable for high-frequency technology or any other electrotechnical application.

[0097] The electrical connector 2 and the mating electrical connector 3 can, in principle, be designed in any way, and in particular can have any number of contact elements 4, 5 and mating contact elements 7, 8. In the exemplary embodiments, the electrical connector 2 has, purely by way of example, a sleeve-shaped outer conductor contact element 4 in which two inner conductor contact elements 5 extend, each having a sleeve-shaped contact area. For fastening or guiding and for electrical insulation of the contact elements 4, 5 from one another, the inner conductor contact elements 5 in the exemplary embodiments extend through a dielectric 6 or through an insulator.

[0098] The mating connector 3 is designed to correspond to the connector 2 and has one (counter) outer conductor contact element 7 and two (counter) inner conductor contact elements 8.

[0099] In the exemplary embodiments, a frictional connection is provided for connecting the connector 2 to the mating connector 3, preferably an interference fit between the respective contact elements 4, 5 and mating contact elements 7, 8. However, this is not to be understood as a limitation, since in principle the invention can be used with electrical connectors 1 that are connected to each other in any way, for example, screwed together or snapped together.

[0100] The contact element 4, 5 can, in particular, be a contact element 4, 5 manufactured by a die-casting process, preferably made of zinc, aluminum, or an alloy containing zinc and / or aluminum. Such a contact element 4, 5 is generally not particularly temperature-stable, which is why the mechanical and electrical connection with the respective corresponding mating contact element 7, 8 can deteriorate at high temperatures. For example, temperatures above 140 °C can sometimes occur with the high currents present in a high-voltage connector. Especially above 85 °C, the materials manufactured by a die-casting process can easily lose their shape.

[0101] It is proposed here to equip the electrical connector 2 with at least one contact assembly 9, which has a sleeve-shaped contact element 4, 5 made of a metallic first material. This contact element 5 has a first lateral surface 10 for electrical and mechanical contacting of the corresponding mating contact element 7, 8 and a second lateral surface 11 distinct from the first lateral surface 10. The contact assembly 9 also has a limiting element 12 made of a second material distinct from the first material, the second material having a higher temperature resistance than the first material. In particular, the second material has a lower coefficient of thermal expansion than the first material. This limiting element 12 is attached, at least partially, to the second lateral surface 11 of the contact element 4, 5. In this way, the temperature stability of the contact element 4, 5 can be improved.

[0102] In the in the Figures 1 and 2 In the illustrated embodiments, three contact assemblies 9 are provided for the electrical connector 2. A first contact assembly 9 has the outer conductor contact element 4, a second contact assembly 9 has the first inner conductor contact element 5, and a third contact assembly 9 has the second inner conductor contact element 5. However, in principle, supporting only the outer conductor contact element 4 may be sufficient.

[0103] The contact elements 4, 5 of the contact assemblies 9 are according to the embodiments of the Figures 1 and 2 designed to be plugged onto the corresponding mating contact element 7, 8 of the mating connector 3 (see in particular Figure 2The first lateral surface 10 of the respective contact element 4, 5 is therefore an inner surface of the contact element 4, 5, and the second lateral surface 11 for attaching the limiting element 12 is an outer surface of the contact element 4, 5, which faces away from the inner surface. The respective contact element 4, 5 is thus arranged between the respective limiting element 12 and the corresponding counter-contact element 7, 8, thereby providing the desired support.

[0104] The proposed limiting elements 12 can be, as shown, sleeve-shaped, ring-shaped, or at least partially ring-shaped. The second material of the limiting elements 12 is preferably a metallic material, in particular an iron alloy, steel alloy, or brass alloy. The limiting elements 12 extend circumferentially along the second lateral surface 11 of the respective contact element 4, 5 and preferably bear in full contact with the second lateral surface 11.

[0105] The limiting element 12 can be attached directly to the second lateral surface 11 of the contact element 4, 5 by means of a force-fit connection, for example by means of an interference fit between the limiting element 12 and the contact element 4, 5, as shown in Figure 1 depicted.

[0106] In the second embodiment, one possible alternative is the Figure 2The figure shows that the limiting element 12 is attached to the second lateral surface 11 of the contact element 4, 5 via a threaded connection 13 formed between the limiting element 12 and the second lateral surface 11. However, the exact connection technique between the limiting element 12 and the contact element 4, 5 is not essential, provided that the limiting element 12 is able to stabilize the contact element 4, 5 in the connected state.

[0107] For particularly good support of the contact element 4, 5, the limiting element 12 is preferably attached to an axial end section of the contact element 4, 5 provided for connection with the mating contact element 7, 8. The limiting element 12 can, for example, extend from an axial end of the contact element 4, 5, as shown with respect to the outer conductor contact elements 4 in the Figures 1 to 3shown. However, it is not absolutely necessary for the limiting element 12 to extend from the axial end of the contact element 4, 5 (cf. inner conductor contact elements 5 in the Figures 1 and 2 ).

[0108] The use of several boundary elements 12, which, for example, each surround the second lateral surface 11 in a ring shape and are axially spaced apart from each other, in particular axially offset from each other, can also be provided.

[0109] To simplify assembly and to provide a particularly robust connector 2, the contact element 4, 5 can be provided with a first axial stop 14 for the limiting element 12, directly adjacent to the second outer surface 11. Optionally, a second stop 15 can also be provided for the mating contact element 7, 8 of the mating connector 3.

[0110] The examples of implementation of Figures 1 and 2Figures 4 and 5 each show an external support for the contact elements 4 and 5. However, it is also possible, in principle, to provide support for the contact element 4 and 5 via its inner surface, as in the third embodiment of the Figure 3 indicated. Thus, the first lateral surface 10 of the contact element 4, 5, can be in Figure 3 The outer conductor contact element 4 is an outer surface of the contact element 4, 5, and the second outer surface 11 is an inner surface facing away from the outer surface. This configuration can be advantageous, for example, if the outer conductor contact element 4 of the connector 2 is to be inserted into a mating contact element 7 of the mating connector 3 designed as a housing assembly, as in Figure 3 hinted at.

[0111] As can be seen from the example implementation of the Figure 3This does not necessarily mean that all contact elements 4, 5 involved are reinforced by a limiting element 12. In the exemplary embodiment of the Figure 3 The inner conductor contact elements 5 are designed, for example, as pure pin contacts which can be inserted into corresponding mating contact elements 8 of the mating connector 3.

[0112] An exemplary process flow for the manufacture of a corresponding electrical connector 2 is shown. Figure 4 .

[0113] According to a first process step S1, the sleeve-shaped contact element 4, 5 can initially be provided. The contact element 4, 5 can preferably be manufactured by a die-casting technique, in particular from zinc, aluminum or an alloy containing zinc and / or aluminum.

[0114] In a second process step S2, which can be carried out in parallel, but possibly also before or after the first process step S1, the limiting element 12 can be provided.

[0115] In a third process step S3 following the first two process steps S1, S2, the limiting element 12 can be attached at least section by section to the second lateral surface 11 of the contact element 4, 5.

[0116] In principle, the proposed method can also include further process steps for manufacturing the electrical connector 2. For example, the electrical connector 2 can be connected to an electrical cable and / or a busbar. The proposed method can, in principle, be combined with any known process steps for manufacturing any electrical connector.

Claims

1. Contact assembly (9) for an electrical plug-in connector (2), having a sleeve-shaped contact element (4, 5) made of a metallic first material, wherein the contact element (4, 5) has a first lateral surface (10) for making electrical and mechanical contact with a mating contact element (7, 8) of a mating electrical plug-in connector (3) and a second lateral surface (11) different from the first lateral surface (10), the contact assembly comprising a delimiting element (12), preferably made from a second material different from the first material, wherein the delimiting element (12) is fastened to the second lateral surface (11) of the contact element (4, 5) at least in certain portions, characterized in that the delimiting element (12) has a higher high-temperature strength than the contact element (4, 5).

2. Contact assembly (9) according to Claim 1, characterized in that the second material has a lower coefficient of thermal expansion than the first material.

3. Contact assembly (9) according to Claim 1 or 2, characterized in that the first lateral surface (10) a) is an inner surface of the contact element (4, 5), and the second lateral surface (11) is an outer surface, facing away from the inner surface, of the contact element (4, 5); or b) is an outer surface of the contact element (4, 5), and the second lateral surface (11) is an inner surface, facing away from the outer surface, of the contact element (4, 5).

4. Contact assembly (9) according to one of Claims 1 to 3, characterized in that the delimiting element (12) has a sleeve-shaped form or is at least partially in the form of part of a ring.

5. Contact assembly (9) according to one of Claims 1 to 4, characterized in that the second material of the delimiting element (12) is a metallic material, preferably an iron material, steel material or brass material.

6. Contact assembly (9) according to one of Claims 1 to 5, characterized in that the delimiting element (12) extends annularly circumferentially along the second lateral surface (11) of the contact element (4, 5), wherein the delimiting element (12) rests on the second lateral surface (11) at least in certain portions.

7. Contact assembly (9) according to one of Claims 1 to 6, characterized in that the delimiting element (12) is fastened to the second lateral surface (11) of the contact element (4, 5) by a force fit, preferably by means of an interference fit between the delimiting element (12) and the contact element (4, 5).

8. Contact assembly (9) according to one of Claims 1 to 7, characterized in that the delimiting element (12) is fastened to the second lateral surface (11) via a threaded connection (13) formed between the delimiting element (12) and the second lateral surface (11) of the contact element (4, 5).

9. Contact assembly (9) according to one of Claims 1 to 8, characterized in that the delimiting element (12) is fastened to an axial end portion of the contact element (4, 5) that is intended for connection to the mating contact element (7, 8).

10. Contact assembly (9) according to one of Claims 1 to 9, characterized in that the contact element (4, 5) has a first axial stop (14), axially directly adjoining the second lateral surface (11), for the delimiting element (12).

11. Electrical plug-in connector (2), in particular high-voltage plug-in connector, having at least one contact assembly (9) according to one of Claims 1 to 10, wherein the contact element of at least a first one of the contact assemblies (9) mentioned is in the form of an external conductor contact element (4) and / or wherein the contact element of at least a second one of the contact assemblies (9) is in the form of an internal conductor contact element (5) arranged within the external conductor contact element (4).

12. Electrical plug-in connection (1), having an electrical plug-in connector (2) according to Claim 11 and the mating electrical plug-in connector (3).

13. Electrical plug-in connection (1) according to Claim 12, characterized in that the contact element (4, 5) of the electrical plug-in connector (2) is connected by a force fit to the mating contact element (7, 8) of the mating electrical plug-in connector (3) in the connected state of the electrical plug-in connection (2), preferably by means of an interference fit between the contact element (4, 5) and the mating contact element (7, 8).

14. Method for producing an electrical plug-in connector (2), having at least the following method steps: - providing a sleeve-shaped contact element (4, 5) made of a metallic first material, which has a first lateral surface (10) for making electrical and mechanical contact with a mating contact element (7, 8) of a mating electrical plug-in connector (3) and a second lateral surface (11) different from the first lateral surface (10); - providing a delimiting element (12), preferably made of a second material different from the first material, wherein the delimiting element (12) has a higher high-temperature strength than the contact element (4, 5); and - fastening the delimiting element (12) to the second lateral surface (11) of the contact element (4, 5) at least in certain portions.

15. Method according to Claim 14, characterized in that the contact element (4, 5) is produced by a die casting method, preferably from zinc, aluminum or an alloy comprising zinc and / or aluminum.