Connector assembly and connector

Abstract

The present invention relates to a connector assembly. A connector assembly (1) comprises a connector (2) and several electrical conductors (3). The connector (2) has a connector housing (4) in which an axial end region (32) of each electrical conductor (3) is inserted and secured. A contact surface (27) is formed on each electrical conductor (3) or on each contact element (31), which is integrally connected to the respective electrical conductor (3). This contact surface is configured to electrically contact a mating contact surface (26) of a corresponding mating contact element (22) of a mating connector (19). Each contact surface (27) has a directional component in a direction orthogonal to a longitudinal axis of the respective electrical conductor.In the connector housing (4) at least one spring element (15) is arranged for each electrical conductor (3), which is connected to the respective electrical conductor (3) and is designed to press the contact surface (27) against the counter-contact surface (26), which has a directional component in a direction orthogonal to a longitudinal axis direction of the respective counter-contact element, in the direction first orthogonal to the longitudinal axis direction of the respective electrical conductor.

Description

FIELD OF THE INVENTION

[0001] The present invention relates to a connector assembly having the features of patent claim 1 and a plug connection having the features of patent claim 15. TECHNICAL BACKGROUND

[0002] Plug-in connectors are used to transmit data signals and electrical supply currents. The electrical contact between the contact element of the plug-in connector and the corresponding mating contact element of the mating connector is established, particularly in electrical connectors for high currents and high voltages, via contact blades arranged between them, which ensure sufficient contact pressure between the contact element and the mating contact element.

[0003] DE 10 2013 217 256 B3 provides an example of a plug connection with a pin-shaped contact element, a socket-shaped mating contact element, and a contact sleeve with individual contact blades arranged between them. Such a plug connection is used, for example, in electric or hybrid vehicles in the charging path between the charging interface and the battery, in the traction path between the battery and the electric drive, or in other high-voltage paths between the battery and other electrical components.

[0004] The intermediate contact sleeve creates two contact transitions between the contact element and the mating contact element, increasing the transfer impedance in the transmission path between the connector and the mating connector. Oxidation on the contact surfaces of the individual contact components, which occurs over time, particularly when aluminum is used as the contact material, further worsens the transfer impedance in the transmission path. The increasing trend toward transmitting ever higher currents or voltages in electric or hybrid vehicles, particularly in the charging path, is significantly limited by increased transfer impedance in the transmission path.

[0005] This is a situation that needs to be improved.

[0006] For the technical background, reference is made to the following documents. EP 2 690 716 A1 relates to an electrical connection element, comprising a base body with at least one connection section and at least one socket section, which has at least one contact arm for contacting a plug contact that can be inserted into the socket section, wherein the contact arm is divided into at least two partial contacts in a contact region in which contact is made with the inserted plug contact. In addition, the electrical connection element comprises an over-spring surrounding the base body in the region of the socket section, which over-spring arm has at least one over-spring arm that interacts with the contact arm at least in the contact region so that the contact arm can be deflected counter to a restoring force of the over-spring arm. WO 2011 / 053276 A1 relates to socket connections that are designed such that they engage the pin contact orimprove the holding force. FR 2 794 293 A1 relates to a contact element having an element insertable into a cylindrical conductor body. Finally, DE 20 2018 104 493 U1 relates to a spring with a stabilizing feature for use with an electrical connection socket. US 10,116,078 B1 relates to an electrical connection system having a first housing having a first electrical terminal and a terminal hood, and having a second housing configured to mate with the first housing, the second housing having a second electrical terminal and a sliding block. SUMMARY OF THE INVENTION

[0007] Against this background, the object of the present invention is to create a plug connection, in particular for the transmission of higher currents or higher electrical voltages, which has a minimized transfer impedance between the contact elements and the associated mating contact elements.

[0008] According to the invention, this object is achieved by a connector arrangement having the features of patent claim 1.

[0009] Accordingly, it is provided: A connector arrangement comprising a connector and a plurality of electrical conductors, the connector comprising a connector housing in which an axial end portion of each electrical conductor is inserted and fixed, wherein on each electrical conductor or on each contact element, which is connected in one piece to the respective electrical conductor, a contact surface is formed which is configured to electrically contact a mating contact surface of an associated mating contact element of a mating connector, wherein the respective contact surface in each case has a directional component in a first direction orthogonal to a longitudinal axis direction of the respective electrical conductor, wherein at least one spring element is arranged in the connector housing for each electrical conductor, which spring element is connected to the respective electrical conductor and is configured to press the contact surface against the mating contact surface, which has a directional component in a direction orthogonal to a longitudinal axis direction of the respective mating contact element, in the first direction orthogonal to the longitudinal axis direction of the respective electrical conductor.

[0010] The insight / idea underlying the present invention is to minimize the number of contact transitions in the plug connection: for this purpose, on the one hand, a direct contact is realized between the contact partners of the plug connector and the mating connector without the interposition of a contact sleeve with contact blades.

[0011] On the other hand, the contact surface of the contact partner belonging to the connector is formed either directly in the individual electrical conductor or in a contact element formed in one piece with the individual electrical conductor.

[0012] To ensure sufficient contact pressure between the two contact partners, i.e., between the individual contact surface in the connector and the corresponding mating contact surface in the mating connector, at least one spring element is provided for each electrical conductor inserted into the connector. This spring element presses the electrical conductor and thus the contact surface belonging to the electrical conductor against the corresponding mating contact surface in the mating connector. The electrical conductor is thus arranged between the spring element and the corresponding mating contact element.

[0013] In order to minimize the installation space for the plug-in connection, when the electrical plug-in connection is plugged in, the electrical conductors and the associated mating contact elements are each arranged in a direction that is orthogonal to the longitudinal axis of the electrical conductors and, at the same time, to the longitudinal axis of the mating contact elements. The longitudinal axis of the electrical conductor and the associated mating contact element are thus spaced apart from one another laterally, i.e., they are arranged in the direction of the transverse extent of the electrical conductor and the associated mating contact element. In this context, it should be noted that a longitudinal extent or a longitudinal axis of a body is to be understood as the greatest extent or the direction with the greatest extent of a body, and transverse extent is to be understood as the smaller extent of a body.

[0014] The contact surface of each electrical conductor or each contact element that is integrally connected to the respective electrical conductor thus has a directional component that is orthogonal to the longitudinal axis of the electrical conductor or the mating contact element. Consequently, each spring element connected to an electrical conductor presses the contact surface of the electrical conductor or the contact surface of the contact element that is integrally connected to the electrical conductor against the mating contact surface on the associated mating contact element in a direction that is first orthogonal to the longitudinal axis of the electrical conductor.

[0015] During operation, a constant and sufficient force is exerted from the contact surface to the corresponding mating contact surface via the individual spring elements in a direction orthogonal to the longitudinal axis of the electrical conductor. The contact surface, which is complementary to the mating contact surface, thus makes full contact with the corresponding mating contact surface without any air inclusions. Oxidation or corrosion of the contact surface and the mating contact surface is thus advantageously eliminated. This also prevents a deterioration in the transfer impedance due to surface oxidation on the contact or mating contact surfaces over the operating period.

[0016] In addition, age-related contact fatigue, so-called contact relaxation, is prevented in the contact area of ​​the electrical conductor or in the contact area of ​​the contact element integrally connected to the electrical conductor due to the permanent application of force by at least one spring element.

[0017] The connector assembly is preferably a connector assembly for transmitting a high current or a high electrical voltage. A high current is understood here and below to mean a current to be transmitted between typically 300 A and 600 A in an electric or hybrid vehicle. The range of the high electrical voltage to be transmitted in an electric or hybrid vehicle is preferably between 450 V and 1500 V, and particularly preferably between 750 V and 1000 V.

[0018] The electrical conductor is preferably designed as a flat electrical conductor. Here and below, an electrical conductor is understood to be an electrical conductor with a first transverse extension and a second transverse extension, in which the first transverse extension is larger, preferably several times larger, than the second transverse extension. Preferably, the surface of the electrical conductor formed by the first transverse extension and the longitudinal extension is planar. Preferably, the first transverse extension of the electrical conductor is oriented orthogonally to the second transverse extension, thus creating a rectangular cross-sectional profile.

[0019] Depending on the application, the electrical flat conductor can be designed as a busbar, i.e., a rigid electrical flat conductor, or as a cable whose strands are compacted to each other at the axial end. In the latter case, the electrical flat conductor is rigid at least in one axial end region. Finally, due to its dimensions and the material used, the electrical flat conductor can also exhibit a certain degree of flexural elasticity for flexible installation in the body of the electric or hybrid vehicle.

[0020] The connector assembly preferably includes two electrical conductors for transmitting direct or alternating current. However, three electrical conductors for transmitting three-phase current or an integer multiple of electrical conductor pairs for transmitting multiple direct and / or alternating currents are also conceivable.

[0021] The individual electrical conductors are preferably secured in the connector housing of the connector assembly by means of a form-fitting connection, by means of a suitable shaping of a specific longitudinal section of the individual electrical conductors and a suitable shaping of a corresponding channel for the electrical conductor in the connector housing. However, a force-fitting and possibly even a material-fitting fixation of the individual electrical conductors in the connector housing is also conceivable.

[0022] The connector housing, which is designed in one or more parts and preferably in two parts, has an opening through which the electrical conductors are inserted. For contacting the electrical conductors with the associated mating contact elements, the connector housing has a further opening through which the mating contact elements of the mating connector can be inserted into a common receiving chamber or into individual receiving chambers within the connector housing.

[0023] The connector housing incorporates suitable features for the technical functions of fastening, securing, sealing, etc., based on current knowledge. Finally, the connector housing must be manufactured from a suitable dielectric material and dimensioned to meet the dielectric strength requirements for the clearance and creepage distances necessary for the transmission of high currents or high electrical voltages.

[0024] The electrical conductor and the contact element integrally connected to the electrical conductor are preferably each made of a metallic material with good electrical conductivity, high friction resistance, and a low specific density. Aluminum or, alternatively, copper is preferably used. To improve contact resistance, silver is preferably used as the coating material.

[0025] The one-piece connection between the electrical conductor and the associated contact element is preferably achieved by means of a material bond, for example by soldering or welding.

[0026] Advantageous embodiments and further developments emerge from the further subclaims and from the description with reference to the figures of the drawing.

[0027] According to the invention, the contact surface has, in addition to the directional component directed in a first direction orthogonal to the longitudinal axis of the electrical conductor, a directional component in a second direction orthogonal to the longitudinal axis of the electrical conductor and to the first orthogonal direction. Consequently, the mating contact surface of the associated mating contact element not only has a directional component directed in a direction orthogonal to the longitudinal axis of the mating contact element, but also a directional component in the longitudinal axis of the mating contact element.

[0028] Additionally, a fastening element is arranged in the connector housing, which is designed to secure the connector to the mating connector with a corresponding fastening element in the mating connector. The fastening element of the connector and the complementary fastening element of the mating connector ensure sufficient contact pressure between the contact surfaces and the corresponding mating contact surfaces in the longitudinal axis direction of the mating contact element.

[0029] In this case, a normal force acts from the individual contact surfaces of the connector to the corresponding mating contact surfaces of the mating connector, each of which has a directional component in the longitudinal axis direction of the mating contact element and at the same time a directional component orthogonal to the longitudinal axis direction of the mating contact element.

[0030] Since the individual contact surfaces and the associated mating contact surfaces each have a directional component in the longitudinal axis of the mating contact element and a directional component orthogonal to the longitudinal axis of the mating contact element, a relative movement occurs between the individual contact surfaces and the associated mating contact surfaces along the contact surface or the mating contact surface during the mating process. This represents a frictional movement of the contact surface against the associated mating contact surface (sliding friction), which is advantageously associated with abrasion of an oxide layer on the contact surface and on the mating contact surface. When the connector and mating connector are mated, the contact force applied by the fastening element and acting in the mating direction is advantageously reduced due to static friction.

[0031] The contact surface and the associated mating contact surface, each of which has a directional component in the longitudinal axis of the mating contact element and a directional component transverse to the longitudinal axis of the mating contact element, can each be either planar or curved. With a curved or curved shape, either a convex or concave curvature in one or two directions is possible. A planar contact surface and a planar mating contact surface each have the same orientation. A curved contact surface and a curved mating contact surface each have the same curvature.

[0032] In a preferred embodiment, the fastening element is a fastening screw. The fastening screw is directed in its longitudinal extension, i.e. with the screw shaft, in the longitudinal axis direction of the mating contact elements and can be screwed into a screw sleeve in the mating connector. The screw sleeve has an internal thread corresponding to the external thread of the fastening screw. The screw sleeve thus represents the fastening means of the mating connector or the counter-fastening means of the fastening. The fastening screw can be inserted into the connector housing via a feedthrough formed in the connector housing in the longitudinal axis direction of the mating contact elements. Fastening via a screw connection offers the advantage of achieving a sufficiently high fastening and contact force and thus secure fastening or contacting.

[0033] As an alternative to a screw connection, a snap-in connection is also conceivable as a fastening mechanism between the connector and the mating connector. For this purpose, locking elements such as locking hooks, locking tabs, locking lugs, spring arms, snap hooks, etc. can be provided on the connector housing, and corresponding counter-locking elements such as locking recesses, snap receptacles, etc. can be provided on the mating connector housing. To ensure sufficient contact pressure in the longitudinal axis direction of the mating contact elements between the individual contact surfaces and the corresponding mating contact surfaces, an additional spring element must be provided for each electrical conductor in a snap-in connection. This spring element is connected to the respective electrical conductor and presses the respective contact surface against the corresponding mating contact surface in the longitudinal axis direction of the mating contact elements.The additional spring element, which exerts a spring force on an electrical conductor in the longitudinal axis direction of the mating contact elements, is therefore to be arranged in the longitudinal axis direction of the mating contact elements on the side of the electrical conductor within the connector housing which is opposite the side of the electrical conductor with the contact surface.

[0034] Analogously, the spring element which exerts a spring force on an electrical conductor transversely to the longitudinal axis direction of the mating contact elements is to be arranged in a direction transversely to the longitudinal axis direction of the mating contact elements on the side of the electrical conductor within the connector housing which is opposite the side of the electrical conductor with the contact surface.

[0035] By arranging the spring elements outside the contact area, the number of contact transitions and thus the transfer impedance in the contact area can be minimized while simultaneously developing a contact pressure between the two contact partners. To achieve the contact pressure between the two contact partners and thus transfer the spring tension from the spring element to the electrical conductor, the spring element must be positioned in a preloaded state between the connector housing and the electrical conductor.

[0036] In a preferred embodiment, the spring element is formed as a spring tab in a metal plate, preferably in a metal sheet. Such an implementation facilitates the formation of multiple spring tabs in the metal plate. Applying multiple spring tabs of a metal plate to an electrical conductor is particularly advantageous for electrical conductors with multiple parallel contact surfaces and / or for a flat cross-sectional geometry of the electrical conductor, for example, in the case of a flat electrical conductor. The metal plate with the individual spring tabs can thus be arranged between the connector housing and the flat electrical conductor, parallel to the flat electrical conductor and thus parallel to the individual parallel contact surfaces.In this way, a parallel and equal force transmission from the individual spring tabs to the individual contact surfaces of the electrical conductor is ensured in a direction transverse to the longitudinal axis of the mating contact elements.

[0037] Instead of a spring tab that is punched out of a metal plate and bent, any other spring variant can be used for the spring element, for example a coil spring or an element made of an elastomer.

[0038] Since the contact surface or the mating contact surface, in a preferred embodiment, each has a directional component in a longitudinal axis direction of the mating contact elements and a directional component transverse to the longitudinal axis direction of the mating contact elements, several design variants for contacting are conceivable with a laterally spaced arrangement of the longitudinal axes of the electrical conductor and the associated mating contact element in the plugged-in state of the connector and the mating connector, as shown below. It should be noted that the longitudinal axes of the electrical conductor and the mating contact element are not only laterally spaced from one another, but are preferably also oriented orthogonally to one another.

[0039] In a first variant of such a contact, the electrical conductor is to be reshaped in the axial end region transversely to the longitudinal axis in such a way that a contact surface is formed in the reshaped region which has not only a directional component in the longitudinal axis direction of the counter-contact element, but also a directional component transversely to the longitudinal axis direction of the counter-contact element.

[0040] In the case of an electrical flat conductor whose larger first transverse extension runs parallel to the longitudinal axis of the mating contact element, a forming, preferably a punching and bending, of the electrical conductor in a first orthogonal direction to the longitudinal axis of the electrical conductor, ie in the direction of the smaller second transverse extension, is necessary in order to form such a contact surface in the axial end region of the electrical conductor.

[0041] Such a forming process for an electrical flat conductor positioned and oriented in this way relative to the mating contact element can, for example, be a lamellar or tab-shaped formed region created from the electrical flat conductor by punching and bending. While the lamellar region is connected to the flat conductor at both ends, the tab-shaped region is connected to the flat conductor at only one end.

[0042] In a second variant of a contact, the electrical conductor is integrally connected in the axial end region to a contact element on which a contact surface is formed with a directional component in a longitudinal axis direction of the mating contact element and a directional component transverse to the longitudinal axis direction of the mating contact element. The contact element can be connected to the electrical conductor transversely to the longitudinal axis of the electrical conductor or at the front end of the electrical conductor. In both cases, it is essential that the contact element extends from the electrical conductor in the direction of the longitudinal axis of the mating contact element to be contacted, thus enabling contact with the mating contact element.

[0043] Such a formation on the contact element can, for example, be lamellar, tab-shaped, rib-shaped or nose-shaped.

[0044] In a third variant of a contact, a lateral boundary of the electrical conductor relative to the longitudinal axis of the electrical conductor is shaped in such a way that the shaped lateral boundary of the electrical conductor forms the contact surface. The lateral surface of the electrical conductor is shaped to complement the mating contact surface of the corresponding mating contact element. The shape of the lateral surface as a contact surface refers to all aspects of the surface profile, such as orientation, curvature, etc.

[0045] In the case of an electrical flat conductor, the side surface formed as a contact surface according to the third variant is preferably the smaller side surface. The smaller second transverse extension of the electrical flat conductor runs parallel to the longitudinal axis of the mating contact element.

[0046] With such an orientation of the electrical flat conductor relative to the longitudinal axis of the mating contact element, it is also conceivable to form a contact surface on a tab-shaped portion of the electrical flat conductor. Finally, it is also possible to connect a contact element with a tab-, rib-, or nose-shaped formation to the smaller side surface in the axial end region of the electrical flat conductor.

[0047] To transmit direct or alternating current, two electrical conductors are inserted in parallel into a connector which, when plugged in, make contact with two mating contact elements arranged parallel in the mating connector. Since the longitudinal axes of the two electrical conductors are arranged laterally to the longitudinal axes of the corresponding mating contact elements when plugged in, the two parallel electrical conductors can be spaced closer together in the intermediate area between the two mating contact elements or further apart and enclose the two mating contact elements. To transmit multiple direct or alternating currents, the individual pairs of electrical conductors and the corresponding pairs of mating contact elements must be arranged parallel to one another.

[0048] To increase the current-carrying capacity between the electrical conductor and the associated mating contact element, several parallel contact surfaces are formed on the electrical conductor in such a way that they can each be contacted with a corresponding mating contact surface on the mating contact element. The parallel contact surfaces can, for example, each be formed on one of several parallel formed areas on the electrical conductor.

[0049] Alternatively, the parallel contact surfaces can each be formed on a common contact element that is integrally connected to the electrical conductor. Finally, each of the parallel contact surfaces can also be formed on a separate contact element that is integrally connected to the electrical conductor.

[0050] Since a contact surface and an associated mating contact surface cannot necessarily have exact planarity and exact parallelism to one another, which impairs the transfer impedance, in a preferred extension of the contacting system the individual contact surface is divided into several partial contact surfaces. Such a technical measure increases the number of contact points between the contact surface and the mating contact surface and thus improves the transfer impedance. In a lamellar or tab-shaped region of the contact surface of the electrical conductor, the number of contact points can be achieved by slitting the lamellar or tab-shaped regions. The number of contact points can also be increased in the case of a rib-, nose-, or tab-shaped contact region of a contact element that is integrally connected to an electrical conductor by slitting the rib-, nose-, or tab-shaped contact regions.

[0051] In a further preferred embodiment of the invention, each contact surface has a structured surface, preferably a ridged surface. The structured surface of the contact surface can also have a fine structure consisting of pointed elevations, sharp-edged teeth, or sharp-edged ridges. The structured surface of the contact surfaces only slightly impairs the transfer impedance, but allows an oxide layer on the mating contact surface to be broken up during the mating process. Additionally, the mating contact surfaces can also each have a structured surface for breaking up an oxide layer on the associated contact surface.

[0052] Due to the latent loading of the electrical conductors with the spring force of the associated spring elements, in combination with material fatigue of the dielectric material of the mating connector housing, this can lead to undesired displacement or undesired tilting of the associated mating contact elements over time. To mechanically stabilize the contacting system, a clamping element is inserted into a feedthrough formed in the connector housing in the longitudinal axis direction of the mating contact elements, and into a recess formed in the mating connector housing in alignment with the feedthrough of the connector housing. The clamping element is inserted into the recess of the mating connector housing in such a way that the clamping element is connected to the areas of the mating connector housing adjacent to the recess in a force-locking manner, preferably via a press fit.

[0053] The interference fit between the clamping element and the mating connector housing advantageously results in material compaction and thus increased material strength in an area of ​​the mating connector housing where material fatigue would occur without clamping with a clamping element. This advantageously prevents displacement or tilting of the mating contact element, thus increasing the transfer impedance and, in an extreme scenario, loss of contact between the electrical conductors and the associated mating contact elements.

[0054] The clamping element is preferably made of a dielectric material. In a preferred arrangement of the contact partners, in which the two mating contact elements are arranged between the two electrical conductors, the clamping element is arranged in a recess between the two mating contact elements within the mating connector. The clamping element, in which the fastening screw and the associated screw sleeve are arranged when the connector is plugged in, has a sleeve-shaped area.

[0055] To achieve a clamping effect, the clamping element has at least two clamping jaws, which extend radially outwards from the sleeve-shaped region of the clamping element in two opposite directions. These two clamping jaws are each arranged in a recess formed between the two mating contact elements and prevent displacement or tilting of the mating contact elements. For better mechanical stabilization of the clamping element within the mating connector, four clamping jaws are formed on the clamping element, each of which extends radially outwards from the sleeve-shaped region in four mutually orthogonal directions. The two additional clamping jaws are anchored in a slot between two contact areas of the two mating contact elements.

[0056] In a further arrangement of the contact partners, in which the two electrical conductors are arranged between the two mating contact elements, two clamping elements are preferably provided, each of which is force-fitted into a recess between the respective mating contact element and the outer wall of the mating connector housing. The two clamping elements are suitable for connection to the fastening element, in particular to the fastening screw.

[0057] Each clamping element can be connected to the connector housing, preferably in a form-fitting manner, for example via a snap-in connection. Each dielectric clamping element must also be connected to the fastening element, in particular to a metal fastening screw. For this purpose, a metal sleeve is preferably provided, which is connected to the metal fastening screw via a screw connection and to the dielectric clamping element via a press fit.

[0058] The invention also covers a plug-in connection. The plug-in connection comprises the connector assembly with the connector and a mating connector corresponding to the connector. The contact surface formed on each electrical conductor of the connector assembly or the contact surface formed on each contact element of the connector assembly contacts the corresponding mating contact surface formed on a corresponding mating contact element of the mating connector.

[0059] The features already explained for the connector arrangement are also applicable analogously to the plug connection.

[0060] The above-mentioned configurations and further training courses can be combined as desired, where appropriate. TABLE OF CONTENTS OF THE DRAWING

[0061] The present invention will be explained in more detail below with reference to the exemplary embodiments shown in the schematic figures of the drawing. In the drawings: Fig. 1A, 1B an exploded view of the plug connector arrangement according to the invention and the mating plug connector, Fig. 2A, 2B a longitudinal sectional view and a plan view of a first embodiment of a contact, Fig. 3A, 3B a longitudinal sectional view and a plan view of a second embodiment of a contact, Fig. 4A, 4B a longitudinal sectional view and a plan view of a third embodiment of a contact, Fig. 5A, 5B a longitudinal sectional view and a plan view of a fourth embodiment of a contact, Fig. 6A, 6B a longitudinal sectional view and a plan view of a fifth embodiment of a contact, Fig. 7A, 7B, 7C, 7D a plan view, a longitudinal sectional view, a first and a second cross-sectional view of the plug connection according to the invention in the unmated state, Fig. 7E, 7F, 7G, 7H a plan view, a longitudinal sectional view, a first and a second cross-sectional view of the plug connection according to the invention and Fig.7I, 7J, 7No cross-sectional view, a first and a second longitudinal section view of the mating connector in the unmated state.

[0062] The accompanying drawing figures are intended to provide a further understanding of embodiments of the invention. They illustrate embodiments and, in conjunction with the description, serve to explain principles and concepts of the invention. Other embodiments and many of the noted advantages will become apparent upon review of the drawings. Elements of the drawings are not necessarily shown to scale relative to one another.

[0063] In the figures of the drawing, identical, functionally identical and acting elements, features and components are provided with the same reference symbols, unless otherwise stated.

[0064] In the following, the characters are described coherently and comprehensively. DESCRIPTION OF EMBODIMENTS

[0065] The following exploded view will be used to Fig. 1A the structure of the connector assembly and the exploded view in Fig. 1B The structure of the corresponding mating connector is explained: The connector assembly 1 has a connector 2 and two electrical conductors 3. Since the two electrical conductors 3 serve not only as connecting elements to an electrical unit or to another connector, but also as electrical contacts of the connector 2, they are also to be understood as components of the connector 2. The connector 2 has a connector housing 4. The two electrical conductors 3, which are preferably designed as electrical flat conductors, can be inserted into the connector housing 4 through a lateral opening 5 of the connector housing 4. The opening 5 of the connector housing 4 is formed by a Fig. 1AThe housing cap, not shown, belonging to the connector housing 4 can be closed.

[0066] Furthermore, a feedthrough 6 is formed in the connector housing 4, transverse to the longitudinal axis of the electrical conductors 3, into which feedthrough a clamping element 7 is inserted. The clamping element 7 is fixed to the connector housing 4 via a locking element 8 with an associated counter-locking element, which is formed on the inner wall of the feedthrough 6. The clamping element 7 has a feedthrough 9. The screw shaft of a fastening screw 11 is inserted through a first end 10 of the feedthrough 9, which screw shaft protrudes from a second end of the feedthrough 9 for screwing to a screw sleeve of the mating connector. To fasten the metallic fastening screw 11 in the feedthrough 9 of the dielectric clamping element 7, a metallic sleeve 12 is pressed into the feedthrough 9 of the clamping element 7 at the first end 10.The fastening screw 11 is fastened to the metallic sleeve 12 by means of a screw connection between the internal thread of the metallic sleeve 12 and the external thread of the fastening screw 11.

[0067] Each electrical conductor 3 has several lamellar formed regions 13, which serve as contact regions of the electrical conductor 3. The Fig. 1A The electrical conductors 3 shown, for example, each have two lamellar formed regions 13. To increase the number of contact points, the individual lamellar formed regions 13 are as shown in Fig. 1A indicated additionally slotted. The two electrical conductors 3, together with an associated metal plate 14, on which several spring elements in the form of spring tabs 15 are formed, are inserted through the lateral opening 5 into the connector 2.

[0068] The two metal plates 14 with the shaped spring tabs 15 are in the Fig. 1A In the variant of a connector 2 shown, the spring tabs 15 are arranged between the outer wall 16 of the connector housing 4 and the electrical conductor 3 in order to press the electrical conductor 3 with the associated spring tabs 15 against an inner wall 17 formed in the connector housing 4. For this purpose, the inner wall 17 has a shape that is complementary to the shape of the electrical conductor 3 plus the lamellar-shaped regions 13. The electrical conductors 3, which are designed as flat electrical conductors, each have a longitudinal section 18, for example, which is S-shaped and is pressed against a correspondingly shaped inner wall 17 of the connector housing 4 by means of the housing cap. In this way, a positive-locking fixation of the electrical conductors 3 to the connector housing 4 is realized.

[0069] The mating connector 19 has according to Fig. 1B a mating connector housing 20 with an opening 21 through which two mating contact elements 22 are inserted into corresponding holding regions 23 formed in the mating connector housing 20. The mating contact elements 22 each have a number of mating contact regions 24 that corresponds to the number of contact regions, i.e., the number of deformed regions 13, of the electrical conductors 3. The two mating contact regions 24, together with the connecting connection region 25, form a U-shaped mating contact element 22.

[0070] At the axial end of each of the two mating contact regions 24, which have a pin-shaped longitudinal extension and a rectangular transverse extension, a mating contact surface 26 is formed. Each mating contact surface 26 of the mating contact element 22 has a corresponding surface profile to the associated contact surface 27, which is formed in a contact region of the associated electrical conductor 3. Thus, the individual contact surface 27 of each electrical conductor 3, as well as the individual mating contact surface 26 of each mating contact element 22, each has a directional component in or opposite to the longitudinal axis direction of the mating contact element 22 and a directional component orthogonal to the longitudinal axis direction of the mating contact element 22.

[0071] Through the opening 21 of the mating connector housing 20, a metallic screw sleeve 28 with an internal thread complementary to the external thread of the fastening screw 11 is inserted as a fastening element of the mating connector 19 into an associated holding area 29 which is formed in the mating connector housing 20.

[0072] When the connector 2 and the mating connector 19 are plugged in, contact is possible between the contact surfaces 27 of the two electrical conductors 3 and the corresponding mating contact surfaces 26 of the mating contact elements 22. For contacting the contact surfaces 27, which are formed on the electrical conductors 3 and the contact elements 31 connected in one piece with the electrical conductors 3, with the corresponding mating contact surfaces 26 of the mating contact elements 22, the contact surfaces 27 are accessible for the corresponding mating contact surfaces 26. For this purpose, the connector housing 4 has, in the illustration of the Fig. 1A There is another opening in the rear and lower area.

[0073] Before the connector arrangement 1 according to the invention, the associated connector 2 and the associated mating connector 19 in the unplugged state and in the plugged state are shown in various views and sections in the Figures 7A to 7Kare explained in detail, the individual characteristics of a contact are presented schematically below: From the Figures 2A and 2B A first embodiment of a contact between two electrical conductors 3 and two associated mating contact elements 22 emerges, in which the mating contact elements 22 are arranged between the two electrical conductors 3 in the plugged-in state of the plug connection 30. The two electrical conductors 3 are each designed as electrical flat conductors, with the larger transverse extent of the electrical flat conductor being oriented parallel to the longitudinal axis of the mating contact elements 22.

[0074] The lamellar-shaped regions 13 of the electrical conductors 3 are thus directed in the direction of the fastening screw 11. The individual contact surfaces 27 of the electrical conductors thus have a directional component in the longitudinal axis direction of the mating contact elements 22, in particular in the direction of the mating connector 19, and a directional component orthogonal to the longitudinal axis direction of the mating contact elements 22, i.e., in the direction of the fastening screw. The spring tabs 15 of the metal plates 14 are arranged outside the electrical conductors 3 and press the contact surfaces 27 of the electrical conductors 3 transversely to the longitudinal axis direction of the mating contact elements 22 against the corresponding mating contact surfaces 26 of the mating contact elements 22.The fastening screw 11, which is screwed into the corresponding screw sleeve 28, presses the connector housing 4 against the mating connector housing 20 and thus the contact surfaces 27 of the electrical conductors 3 in the longitudinal axis direction of the mating contact element 22 against the mating contact surfaces 26 of the mating contact elements 22.

[0075] In a second form of contact according to the Figures 3A and 3B The electrical conductors 3 are arranged between the corresponding mating contact elements 22. The metal plates 14 with the corresponding spring tabs 15 are thus arranged within the electrical conductors 3 and press the lamellar, outwardly formed regions 13 with the contact surfaces 27 formed therein against the mating contact surfaces 26 of the corresponding mating contact elements 22.

[0076] In the Figures 4A and 4BIn the third embodiment of contacting shown, the contact areas of the electrical conductors 3 are directed inwards towards the fastening screw 11. In contrast to the first embodiment of contacting, the contact surfaces are not formed in the electrical conductor 3, but rather are each realized on a rib-, nose-, lamellar-, or tab-shaped contact element 31, which is integrally connected, preferably by a material bond, to the associated electrical conductor 3.

[0077] In a fourth form of contact according to the Figures 5A and 5B In contrast to the first three embodiments, the electrical conductors 3 designed as electrical flat conductors have an orientation of the larger transverse extent of the electrical flat conductors which is oriented orthogonally to the longitudinal axis of the mating contact elements 22.

[0078] The contact surface 27 of the individual electrical conductor 3 is formed on a lateral surface 44 of the electrical conductor 3—namely, the lateral surface 44 of the electrical conductor 3 with the smaller transverse extension—which is arranged transversely to the longitudinal axis of the electrical conductors 3. The lateral surface 44 of the electrical conductors 3 is shaped such that it has a directional component in the longitudinal axis direction of the mating contact element 22 and a directional component orthogonal to the longitudinal axis direction of the mating contact element 22.

[0079] In a fifth form of contact according to the Figures 6A and 6Bthe larger transverse extent of the electrical flat conductors is also oriented orthogonally to the longitudinal axis of the mating contact elements 22. In the fifth embodiment, an axial end region 32 of the electrical conductors 3 is deformed such that a deformed region 13 with a contact surface 27 is formed at the axial end region 32 of the electrical conductors 3, which has a directional component in the longitudinal axis direction of the mating contact element 22 and a directional component orthogonal to the longitudinal axis direction of the mating contact element 22.

[0080] The forming of the axial end region 32 of the electrical conductors 3 is carried out by a punching and bending process. To achieve a higher number of contact points, the formed region 13 can be Fig. 6BAs indicated, it can also be slotted. A modification of the fifth embodiment of a contact is also conceivable, in which the formed region 13 is realized via a correspondingly shaped contact element 31, which is connected in one piece, for example by means of a material connection, to the axial end region 32 of the individual electrical conductor 3.

[0081] In the following Figures 7A to 7K is based on the first occurrence of contact according to the Figures 2A and 2B the connector assembly 1, the connector 2, the mating connector 19 and the plug connection 30 are explained in detail: In the unplugged state of a connector assembly 1 according to the invention according to the Figures 7A, 7B, 7C and 7D Two electrical conductors 3, each designed as electrical flat conductors, are inserted into the connector housing 4 of the connector 2. An S-shaped longitudinal section 18 of each electrical conductor 3 is located according to Fig. 7Bpositively against a correspondingly curved inner wall 17 of the connector housing 4. To fix each electrical conductor 3 in the connector housing 4, a housing cap (not shown for reasons of clarity) is arranged in the lateral opening 5 of the connector housing 4. This housing cap is fixed to the connector housing 4 and presses the two electrical conductors against the inner wall 17 of the connector housing 4.

[0082] In the axial end region 32 of each electrical conductor 3, two lamellar-shaped regions 13 are formed, for example, which each have a plurality of contact points for contacting an associated mating contact element 22 via a plurality of slits. On each lamellar-shaped region 13 of the electrical conductor 3, a contact surface 27 is formed with a directional component in the longitudinal axis direction of the mating contact element 22 and a directional component orthogonal to the longitudinal axis direction of the mating contact element 22.

[0083] Each electrical conductor 3 is pressed in the axial end region 32 with the lamellar-shaped formed regions 13 against a correspondingly shaped inner wall 17 of the connector housing 4 by the spring force of several spring tabs 15. The individual spring tabs 15 are formed on a metal plate 14, which is arranged between the outer wall 16 of the connector housing 4 and the axial end region 32 of the individual electrical conductor 3.

[0084] In order to contact the contact surfaces 27 of the electrical conductors 3 with mating contact surfaces 26 of associated mating contact elements 22, the connector housing 4 of the connector 2 has receiving chambers 33 in the area of ​​the contact surfaces 27 for receiving the mating contact elements 22 (see the Figures 7C and 7D ).

[0085] A clamping element 7 is inserted into a passage 6, which is formed in the connector housing 4, in particular in the inner wall 17 of the connector housing 4, in the direction of the mating connector 19 (see the Figures 7C and 7D ).

[0086] The clamping element 7 protrudes from the feedthrough 6 of the connector housing 4 and into a recess 34, which is aligned with the feedthrough 6 of the connector housing 4 in the mating connector housing 20. The clamping element 7 is inserted into the recess 34 when the fastening screw 11 is fastened in the screw sleeve 28. For this purpose, the clamping element 7 is connected to the fastening screw 11. The fastening screw 11 is guided centrally in the clamping element 7. For this purpose, the clamping element 7 has a sleeve-shaped area 35, inside which the fastening screw 11 is arranged.

[0087] For the passage and fastening of the fastening screw 11, a sleeve-shaped fastening section 36 with a passage 9 is formed inside the sleeve-shaped region 35 of the clamping element 7, which is connected to the sleeve-shaped region 35 of the clamping element 7. For fastening the metallic fastening screw 11 to the dielectric fastening section 36 of the clamping element 7, a metallic sleeve 12 is pressed into the sleeve-shaped fastening section 36 of the clamping element 7 and connected to the fastening screw 11 via a screw connection. The screw head 37 of the fastening screw rests on a flange 38 of the metallic sleeve 12. The flange 38 of the metallic sleeve 12 rests on an end face 39 of the clamping element 7, and a flange 40 of the clamping element 7 rests on an end face 41 of the connector housing 4.

[0088] In order to clamp the clamping element 7 to the mating connector housing 20 within the recess 34 of the mating connector housing 20, four clamping jaws 42 are preferably formed on the clamping element 7, which are directed radially outward in a cross-shaped manner from the sleeve-shaped region 35 of the clamping element 7. The clamping jaws 42 of the clamping element 7, which are formed in a cross-shaped manner in the clamping element 7, each have a certain elasticity in order to be press-fitted into the cross-shaped recess 34 in the mating connector housing 20.

[0089] The cross-shaped recess 34 is formed between the holding areas 23 for the mating contact elements 22 and the holding area 29 for the screw sleeve 28 in the mating connector housing 20.

[0090] From the Figures 7I, 7J and 7KThe mating connector 19 is shown with the mating connector housing 20, in which two mating contact elements 22, each with two mating contact areas 24, are arranged. Each mating contact element 22 is U-shaped, with the two mating contact areas 24 being connected to one another via a connecting area 25. Each mating contact element 22 is fastened in an associated holding area 23 formed in the mating connector housing 20. A metallic screw sleeve 28 is mounted in a further holding area 29, which is formed centrally to the other holding areas 23 in the mating connector housing 20.

[0091] The Figures 7E, 7F, 7G and 7Heach represent the plug connection 30 in the plugged-in state of the connector 2 and the mating connector 19: The fastening screw 11 is screwed into the screw sleeve 28, so that the connector 2 and the mating connector 19 are fixed to each other. The mating contact elements 22 of the mating connector 19 are inserted into the receiving chambers 33 within the connector housing 4. The contact surfaces 27 in the deformed regions 13 of the two electrical conductors 3 each contact the mating contact surfaces 26 in the mating contact regions 24 of the mating contact elements 22.

Claims

1. Plug connector assembly (1) having a plug connector (2) and a plurality of electrical conductors (3), wherein the plug connector (2) has a plug connector housing (4), in which an axial end region (32) of each electrical conductor (3) is inserted and fastened, wherein, at each electrical conductor (3) or at each contact element (31) which is in each case connected as a single piece to the respective electrical conductor (3), in each case a contact surface (27) is formed which is configured to electrically contact a mating contact surface (26) of an associated mating contact element (22) of a mating plug connector (19), wherein the respective contact surface (27) has in each case a directional component in a first direction orthogonal to a longitudinal axial direction of the respective electrical conductor, wherein in each case at least one spring element (15) is arranged in the plug connector housing (4) for each electrical conductor (3), which is connected in each case to the respective electrical conductor (3), and is configured to press the contact surface (27) against the mating contact surface (26), which has a directional component in a direction orthogonal to a longitudinal axial direction of the respective mating contact element, in the first direction orthogonal to the longitudinal axial direction of the respective electrical conductor, characterized in that the respective contact surface additionally has a directional component in a second direction orthogonal to the longitudinal axial direction of the electrical conductor (3) and to the first orthogonal direction, and arranged in the plug connector housing (4) is a fastening element (11) which is configured, when connected to a fastening element (28) of the mating plug connector (19), to press in the second orthogonal direction the contact surface (27) of each electrical conductor (3) or each contact element (31) against the mating contact surface (26) of the associated mating contact element (22), said mating contact surface additionally having a directional component in the longitudinal axial direction of the respective mating contact element (22).

2. Plug connector assembly (1) according to Claim 1, characterized in that the fastening element arranged in the plug connector housing (4) is designed as a fastening screw (11), and the fastening element of the mating plug connector (19) is designed as a screw sleeve (28).

3. Plug connector assembly (1) according to Claim 1 or 2, characterized in that the spring elements (15) are arranged in each case on that side of the electrical conductor (3) in the plug connector housing (4) which is situated opposite that side of the electrical conductor (3) on which the contact surface (27) is formed.

4. Plug connector assembly (1) according to one of Claims 1 to 3, characterized in that the spring elements which are connected to the electrical conductor (3) are in each case shaped as a spring tab (15) in a metal plate (14).

5. Plug connector assembly (1) according to one of Claims 1 to 4, characterized in that each electrical conductor (3) is in each case configured in such a way that its longitudinal axis is arranged, in a plugged state of the plug connector (2) and the mating plug connector (19), laterally spaced apart from a longitudinal axis of the associated mating contact element (22).

6. Plug connector assembly (1) according to Claim 5, characterized in that each electrical conductor (3) is deformed in each case laterally with respect to the longitudinal axis of the respective electrical conductor (3) in such a way that the respective contact surface (27) is formed in a deformed region (13) of the respective electrical conductor (3), or each contact element (31) is shaped in each case laterally with respect to the longitudinal axis of the respective electrical conductor (3) in such a way that the respective contact surface (27) is formed in the respective contact element (31).

7. Plug connector assembly (1) according to Claim 6, characterized in that the deformed region (13) of the electrical conductor (3) is deformed in each case preferably as a strip or tab and the contact elements (31) are shaped in each case preferably as a strip, tab, rib or lug.

8. Plug connector assembly (1) according to Claim 5, characterized in that a lateral surface (44) is shaped in each case on each electrical conductor (3) in such a way that the respective contact surface (27) is formed on the lateral surface (44), wherein the lateral surface (44) is arranged transversely to the longitudinal axis of the respective electrical conductor (3).

9. Plug connector assembly (1) according to one of Claims 1 to 8, characterized in that a plurality of contact surfaces (27) are formed in each case on each electrical conductor (3) or in each case on the contact element (31) connected in each case to each electrical conductor (3), or a contact surface (27) is formed in each case on a plurality of contact elements (31) connected in each case to each electrical conductor (3), wherein each contact surface (27) is in each case configured to electrically contact an associated mating contact surface (26) of the associated mating contact element (22).

10. Plug connector assembly (1) according to one of Claims 1 to 9, characterized in that each contact surface (27) has in each case a structured surface, preferably a grooved surface.

11. Plug connector assembly (1) according to Claims 1 to 10, characterized in that in each case a clamping element (7) is inserted into at least one passage (6), which is formed in each case in the plug connector housing (4) in the direction of the mating plug connector (19), and is configured so that it can be inserted into an associated recess (34) which is formed in a mating plug connector housing (20), flush with the respective passage (6) and so that it can be connected to the mating plug connector housing (20) in a force-fitting fashion.

12. Plug connector assembly (1) according to Claim 11, characterized in that the respective clamping element (7) is connected to the fastening element, wherein the fastening element is configured, when connected to the fastening element of the mating plug connector (19), to press the respective clamping element (7) into the associated recess (34) of the mating plug connector housing (20).

13. Plug connector assembly (1) according to one of Claims 1 to 12, characterized in that the electrical conductor (3) is a flat electrical conductor.

14. Plug connector assembly (1) according to one of Claims 1 to 13, characterized in that the electrical conductor (3) is designed to transmit a current in the range between 300 A and 600 A.

15. Plug connection (30) with a plug connector assembly (1) according to one of Claims 1 to 14 and a mating plug connector (19) corresponding to the plug connector (2), wherein the contact surface (27) formed in each case on each electrical conductor (3) and the contact surface (27) formed in each case on each contact element (31) in each case electrically contact the mating contact surface (26) formed in each case on the associated mating contact element (22) of the mating plug connector (19).

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