High-current connector and method for mounting same

Abstract

A high-current connector, comprising an insulating body (1) which has at least one contact carrier (12) having at least one contact chamber (120), which has at least two through-openings on the plug-in side, and at least two electrically conductive plug-in contacts (3) which are arranged parallel to one another in the contact chamber (120) and each have a cable connection region (31) at a first end and a plug-in region (32) opposite at a second end, the plug-in regions (32) of the plug-in contacts being guided through one of the through-openings each of the contact chamber. The high-current plug connector also has an electrically conductive connection element (4) which is inserted into the contact chamber (120) and which has at least two contact receptacles (40), into each of which one of the plug-in contacts (3) is inserted interlockingly and frictionally by its plug-in region (32), and the at least two plug-in contacts (3) are electrically conductively connected to one another by the connection element.

Description

[0001] The invention relates to a high-current connector according to the preamble of independent claim 1.

[0002] Furthermore, the invention relates to a method for assembling a high-current connector according to the preamble of independent claim 9.

[0003] Such high-current connectors typically have at least one insulating body and several plug contacts arranged within it. They are required to transmit high currents, referred to simply as "high currents," to corresponding mating contacts of a mating connector when plugged in. The terms "high currents" and "high currents" mean, in particular, that such a connector can transmit a current of, for example, at least 24 amperes per plug contact, preferably at least 32 amperes, and in a particularly preferred embodiment even 40 amperes or more. Specifically, said plug contacts can be designed, for example, for currents of 70 amperes.

[0004] To achieve the exceptionally high conductivity required for transmitting high currents, particularly strong insertion forces are generally required. These forces are accompanied by correspondingly high insertion and withdrawal forces when the connectors are plugged in and unplugged. Therefore, the mounting of the plug contacts, especially the pin and socket contacts within the insulating body, is subject to stringent requirements. For this purpose, the insulating body may have a detachably mounted contact retaining plate on the cable connection side. This plate incorporates retaining elements, which may be lamellar in design, to ensure particularly stable mounting of the plug contacts within the insulating body. State of the art

[0005] In current technology, it is often required to "bridge" two contacts of a connector, i.e., to connect them electrically. This is often referred to as "splitting" or "Y-distribution" and generally serves to distribute the current from a sufficiently powerful power source to multiple sinks, a process also known as "potential multiplication." One known method involves dividing a cable, such as the strands of a stranded cable, into several sections and distributing them across the connection points of multiple, e.g., two, connectors. However, this technique is questionable from various safety perspectives and is generally discouraged in professional applications.

[0006] Document CN 200976418 Y discloses a cost-effective electrical connection structure manufactured using stamping and bending technology. In this structure, multiple contacts can be manufactured, particularly in one piece, using stamping and bending technology and thereby electrically connected to one another.

[0007] The publication EP 0 735 627 A2 discloses a multi-pole electrical connector. This connector has an insulating housing and plug-in contacts arranged therein. The plug-in contacts consist of contact pins and complementary contact sockets. Several plug-in contacts are arranged in a row perpendicular to their insertion direction. The connected plug-in contacts are electrically connected to each other by at least one connecting pin running in series. The connecting pin and the connected plug-in contacts together form a pole unit, which is inserted into the insulating housing from the outside in the insertion direction.

[0008] Furthermore, a distribution plug unit for electrical installations with 16 A at 240 V is known from publication EP 2 539 966 B1. Metal bridging elements are disclosed for connecting each (plug-in) pin of a first group to a (plug-in) pin of a second group. These are designed in the form of a flat plate that extends essentially in the plane (...) and integrally includes at each end a bent-back section (M) that defines an elastically deformable open sleeve which surrounds and clamps a metal pin (...).

[0009] A disadvantage of this state of the art is that this design is unsuitable for high-current connectors as defined at the outset. Ultimately, the metal pins (of the plug contact) in this design must be of a sufficient length to provide a contact section that can be fully enclosed by the open sleeve. Consequently, their mechanical fastening within the insulating body would be difficult. Therefore, achieving the desired compact design of the high-current connector is mechanically impossible with this type of design.

[0010] The German Patent and Trademark Office has searched the following prior art in the priority application for the present application: DE 195 13 880 A1, DE 11 2012 004 155 T5, GB 853 694 A, US 4,544,220 A, EP 2 536 966 B1, EP 0 735 627 A2, CN 200 976 418 Y.

[0011] Publication US 3,825,874 A describes a common shield connection for multi-core cables, especially for Twinax cables.

[0012] Patent application US 2009 / 0124117 A1 discloses a connector for the detachable connection of multiple cable pairs with a conductor cross-section greater than 10 mm². For this purpose, individual contact elements, which are conductively connected to the cables, can be inserted into an insulating plug housing and / or an insulating socket housing in a snap-fit ​​manner and are retained within the plug or socket housing in a replaceable manner. The snap-fit ​​of the contact elements in the housings is achieved by elastic deformation of the housings. Handling is facilitated by the fact that the housings are made of a material with a hardness that allows the insertion and replacement of the contact elements without the use of tools. Task

[0013] The object of the invention is to provide a compact design for a high-current connector that is also suitable for transmitting high currents of 24 A and more, in particular for transmitting, for example, 70 A.

[0014] This task is solved by the characteristics of independent claims.

[0015] A high-current connector comprises an insulating body with a contact carrier. The contact carrier has at least one contact chamber, which has at least two through-holes on the mating side. Furthermore, the high-current connector has at least two electrically conductive plug contacts arranged parallel to each other within the contact chamber. Each plug contact has a cable connection area at one end and a plug-in area at the opposite end. These plug-in areas are each guided through one of the through-holes of the contact chamber.

[0016] Furthermore, the high-current connector has an electrically conductive connecting element inserted into the contact chamber. This connecting element has at least two contact receptacles, into each of which one of the plug contacts is inserted with its mating area in a form-fitting and force-fit manner. The connecting element electrically connects the at least two plug contacts to each other.

[0017] A procedure for assembling the high-current connector comprises the following steps: A.) Inserting at least one connecting element into at least one cable-connection-side open contact chamber of a contact carrier, such that the connecting element with its contacts is located near plug-side through-openings of the contact chamber; B.) Mounting an insulating body by attaching a contact retaining plate to the contact carrier and thereby simultaneously C.) fixing the at least one connecting element in the insulating body; D.) Crimping at least one electrical conductor of a high-current electrical cable to a cable connection area of ​​at least one plug contact; E.) Cable connection-side insertion of the crimped plug contact and insertion of at least one further plug contact through each contact opening of the contact retaining plate into a common contact chamber of the contact carrier, wherein at least these two plug contacts lock into the insulating body and simultaneously each engage one of the contact receptacles of the connecting element, and thereby F.) electrically conductive connection of these at least two plug contacts locked in the insulating body, namely the crimped plug contact and the at least one further plug contact, by the connecting element. .

[0018] Advantageous embodiments of the invention are specified in the dependent claims.

[0019] In an advantageous embodiment, the plug contacts are socket contacts, particularly for safety reasons.

[0020] Advantageously, the connecting element possesses sufficiently high elasticity to accommodate, hold, and release the plug contacts without damage. This is particularly advantageous for contacting the connecting element with the plug contacts. According to the invention, the plug contacts can thus be automatically connected to the connecting element in a form-fit and force-fit manner when inserted into the insulating body, thereby establishing electrical contact.

[0021] According to the invention, the connecting element is made of metal, in particular brass, and is designed as a flat surface, with its surface running perpendicular to the insertion direction when inserted. This ensures high robustness, excellent long-term stability, and at the same time a small footprint.

[0022] According to the invention, the at least two contact surfaces of the connecting element are each formed by an open ring. This is particularly advantageous because it allows rotationally symmetrical plug contacts to be inserted into it, at least in sections.

[0023] In particular, the open ring can be formed by having at least two contact surfaces of the connecting element each have two crescent-shaped arms whose ends point towards each other. This is particularly advantageous because it allows the desired elasticity to be adjusted while maintaining maximum stability, which is necessary to accommodate the plug contacts with a desired contact force.

[0024] To facilitate the insertion of the plug contacts, the contact chambers in the contact carrier can be open on the cable connection side. The insulating body also features a contact retaining plate that can be detachably fixed to the contact carrier on the plug-side. The plug contacts are guided through this plate and held in place by it. The contact retaining plate interacts with the contact carrier to insert and secure the plug contacts within the insulating body. In particular, the contact retaining plate can incorporate special retaining elements, such as lamellae. This design offers the additional advantage that the connecting element can be positioned between the plug-side through-holes and the contact retaining plate, specifically its retaining elements, such as its lamellae.

[0025] Furthermore, the contact carrier can have hollow cylindrical projections on its through-holes on the plug-in side as touch protection. These projections encompass the plug-in areas of the plug contacts that pass through the through-holes and extend beyond them on the plug-in side. In addition to providing touch protection, these hollow cylindrical projections also serve to increase air and creepage distances and to prevent flashovers even at high voltages. Example of implementation

[0026] An embodiment of the invention is shown in the drawings and is explained in more detail below. The drawings show: Fig. 1a - an insulating body comprising a contact retaining plate and a contact carrier; Fig. 1f the insulating body with inserted contacts in a top view; Fig. 2a - the connecting element from various views; Fig. 3a - the plug contact from various views; Fig. 4a - plug contacts with the connecting element; Fig. 5a - the insulating body with inserted connecting elements and plug contacts inserted or to be inserted.

[0027] The figures contain simplified, schematic representations. In some cases, identical reference symbols are used for elements that are the same but may not be identical. Different views of the same elements may be scaled differently.

[0028] The Fig. 1aFigure 1 shows a contact retaining plate 11 with lamellae 114, which serve to hold plug contacts 3 and the ground contact pin 3'. The plug contacts 3 and the ground contact pin 3' can be inserted through contact openings 110 on the cable connection side. Furthermore, the contact retaining plate 11 has several locking tabs 111, each with a locking window 112 for locking onto a contact carrier 12.

[0029] The Fig. 1bFigure 1 shows the contact carrier 12 in an oblique top view, i.e., with an oblique view of its cable connection side. This contact carrier 12 has several contact chambers 120 open on the cable connection side for receiving two contacts 3 each. Opposite the cable connection side, the contact chambers 120 each have two through-holes, which are not visible in the drawing and therefore are not labeled. On these through-holes, the contact carrier 12 has hollow cylindrical projections 124 on the plug-in side for receiving one plug-in area 32 of the contacts 3 each. Furthermore, the contact carrier 12 has locking pins 121 against which the locking tabs 111 of the contact retaining plate 11 can engage. In addition, the contact carrier 12 has a ground contact chamber, not further specified for clarity, for receiving a ground contact pin 3'.

[0030] The Fig. 1cFigure 1 shows the mounted insulating body 1, i.e., the contact carrier 12, onto which the contact retaining plate 11 is snapped with its locking tabs 111, the locking windows 112 engaging the locking pins 121, and the lamellae 114 engaging in the contact chambers 120. The ground contact pin 3' is also shown.

[0031] The Fig. 1d The contact retaining plate 11 shows the lamellae 114 from the plug-in side.

[0032] The Fig. 1e shows the assembled insulating body 1 in a side view.

[0033] The Fig. 1f shows the insulating body 1 with inserted plug contacts 3 in a top view, i.e. looking at the contact retaining plate 11.

[0034] The Figs. 2a and 2b show a connecting element 4 which has two contact receptacles 40 into which a plug contact 3 with its plugging area 32 can be inserted in a form-fit and force-fit manner.

[0035] The connecting element 4 is made of metal, specifically brass, and has a flat surface. This ensures high robustness, excellent long-term stability, and at the same time a small footprint.

[0036] The at least two contact surfaces 40 of the connecting element 4 are each formed by an open ring. The circular ring shape is particularly advantageous because the plug contacts 3 to be inserted therein are rotationally symmetrical.

[0037] The open ring is formed by the fact that the at least two contact receptacles 40 of the connecting element 4 each have two crescent-shaped arms 41, the ends of which are directed towards each other. The two ends are thus separated from each other by an opening 400. This is particularly advantageous because, by shaping the specific form of the arms, the desired elasticity can be adjusted while maintaining maximum stability. This elasticity is necessary to accommodate the plug contacts 3 with a desired contact force.

[0038] The Figs. 3a and 3b Figure 3 shows the plug connector 3. This has a cable connection area 31 designed as a crimp area and a plug-in area 32. Between them, on the cable connection area side, is a circumferential collar 34. On the plug-in area side, a connection area 30 adjoins the collar 34, with which the plug connector 3 can be inserted into the contact receptacles 40 of the connecting element 4.

[0039] The Figs. 4a and 4bFigure 1 shows two plug contacts 3, each inserted into one of the contact receptacles 40 of the connecting element 4, in an oblique top view and a side view. The respective plugging area 32 is guided through the contact receptacles 40, and the plug contacts 3 contact the connecting element 4 with their connection areas 30. The connecting element 4 encloses the connection areas 30 with its contact receptacles 40 in a form-fitting and force-fit manner.

[0040] The Fig. 5a Figure 1 shows the assembled insulating body 1 with plug contacts 3 that are partly inserted and partly to be inserted. Four connecting elements 4 are each inserted into a contact chamber 120 and fixed in the insulating body 1 by the interaction of the contact retaining plate 11 with the contact carrier 12 snapped onto it.

[0041] The Fig. 5bFigure 1 shows the same arrangement in a side view. It becomes clear that the plug-in areas 32 of the already inserted contacts 3 are received into the hollow cylindrical forms 124, with the hollow cylindrical forms 124 projecting beyond the plug-in areas 32 on the plug-in side.

[0042] Even though the figures show various aspects or features of the invention in combination, it is apparent to the person skilled in the art – unless otherwise stated – that the combinations shown and discussed are not the only possible ones. In particular, corresponding units or sets of features from different embodiments can be interchanged. Reference symbol list

[0043] 1 Insulating body 11 Contact retaining plate 110 Contact opening 111 Locking tab 112 Locking window 114 Louvers 12 contact carrier 120 contact chamber 121 locking pin 124 hollow cylindrical formations 3 Plug contacts 3 Ground contact pin 30 Connection area 31 Cable connection area 32 Plug area 34 Collar 4 Connecting element 40 Contact point 400 Opening 41 Crescent-shaped arms

Claims

1. High-current plug-in connector, having an insulating body (1) with at least one contact carrier (12) with at least one contact chamber (120) which has at least two plug-side passage openings and having at least two electrically conductive plug-in contacts (3) which are or are to be arranged parallel to one another in the contact chamber (120) and which each have, at a first end, a cable connection region (31) and opposite to this, at a second end, a plug-in region (32), wherein the plug-in region (32) of said plug-in contacts is or can be guided through in each case one of the passage openings of the contact chamber, and wherein the high-current plug-in connector further has an electrically conductive connecting element (4) which is inserted into the contact chamber (120) and which has at least two contact receptacles (40), characterized in that in each case one of the plug-in contacts (3) can be automatically connected to the connecting element (4) in an interlocking and force-fitting manner when they are inserted into the insulating body (1) and in the process can make electrical contact with said insulating body, so that each plug-in contact (3) is inserted, by way of its plug-in region (32), in an interlocking and force-fitting manner into in each case one of the contact receptacles (40) of the connecting element (4), as a result of which the at least two plug-in contacts (3) are electrically conductively connected to one another, wherein the connecting element (4) consists of metal and is of flat design, wherein its surface area runs at a right angle in relation to the plug-in direction in the inserted state and wherein the contact receptacles (40) are designed as open rings.

2. High-current plug-in connector according to Claim 1, wherein the plug-in contacts (3) are socket contacts.

3. High-current plug-in connector according to either of the preceding claims, wherein the connecting element (4) has a sufficiently high degree of elasticity in order to receive and to hold the plug-in contacts (3) and to be able to release said plug-in contacts again without destruction.

4. High-current plug-in connector according to one of the preceding claims, wherein the at least two contact receptacles (40) of the connecting element (4) are each formed by an open ring.

5. High-current plug-in connector according to one of the preceding claims, wherein the at least two contact receptacles (40) of the connecting element (4) each have two sickle-shaped arms (41), the ends of which are directed toward one another.

6. High-current plug-in connector according to one of the preceding claims, wherein the contact chambers (120) in the contact carrier (12) are open on the cable connection side, and wherein the insulating body (1) further has a contact holding plate (11) which can be releasably fixed to the contact carrier (12) on the plug-in side and through which the plug-in contacts (3) are guided and on which said plug-in contacts are held, wherein the contact holding plate (11) interacts with the contact carrier (12) for inserting and fixing the plug-in contacts (3) in the insulating body (1).

7. High-current plug-in connector according to Claim 6, wherein the contact holding plate (11) has lamellae (114) for holding the plug-in contacts (3) at least on one side and for interacting with the contact carrier (12) in a fixing manner.

8. High-current plug-in connector according to one of the preceding claims, wherein the contact carrier (12) has, at its passage openings on the plug-in side, hollow-cylindrical mouldings (124) as touch-protection means, which hollow-cylindrical mouldings comprise the plug-in regions (32), which are guided through the passage openings, of the plug-in contacts (3) and project beyond said plug-in regions on the plug-in side.

9. Method for assembling a high-current plug-in connector according to one of the preceding claims, wherein the method comprises the following steps: A.) inserting at least one connecting element (4) into at least one contact chamber (120), which is open on the cable connection side, of a contact carrier (12), so that the connecting element (4), by way of its contact receptacles (40), is arranged in the vicinity of plug-side passage openings of the contact chamber (120); B.) mounting an insulating body (1) by attaching a contact holding plate (11) to the contact carrier (12) and in this way at the same time C.) fixing the at least one connecting element (4) in the insulating body (1); D.) crimping at least one electrical line of an electric high-current cable to a cable connection region (31) of at least one plug-in contact (3); E.) inserting the crimped plug-in contact (3) on the cable connection side and inserting at least one further plug-in contact (3) through in each case one contact opening (110) of the contact holding plate (11) into a common contact chamber (120) of the contact carrier (12), wherein at least these two plug-in contacts (3) each pass through a contact receptacle (40) of the connecting element (4), characterized in that in this way said plug-in contacts are automatically connected to the connecting element (4) in an interlocking and force-fitting manner and make electrical contact with said connecting element and in this way are also electrically connected to one another and at the same time latch in the insulating body (1).

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