Plug-in connector arrangement and plug-in connector

Abstract

The invention relates to a plug-in connector arrangement (100) comprising a plug-in connector (1) and a mating plug-in connector (2), wherein the plug-in connector (1) has a contact chamber (14) with an outer wall (15) and also has a lamella cage (3) with a base element (4), a plurality of contact lamellae (5) and a coupling section (42), wherein the contact lamellae (5) have a contact-making section (41), wherein the lamella cage (3) is arranged in the contact chamber (14), wherein the contact-making sections (41) are pre-bent in the direction of the outer wall (15) with respect to a rear section (6) and a front section (7) of the contact lamellae (5), wherein the mating plug-in connector (2) has a contact element (9) with a bottom side (35), wherein the mating plug-in connector (2) can be shifted at least as far as a first position (P1) with a force of less than 5 N along an insertion direction (E) and, in a second position (P2) of the mating plug-in connector (2), the contact element (9) makes mechanical contact with the coupling section (42) of the lamella cage (3) in such a way that the contact-making sections (41) of the contact lamellae (5) are shifted along a radial direction (R) towards the outer wall (15) and as a result make electrical contact with a contact section (13) of the outer wall (15).

Description

[0001] Description

[0002] title

[0003] Connector arrangement and connectors

[0004] Field of the invention

[0005] The invention relates to a connector assembly and a connector.

[0006] State of the art

[0007] Connector assemblies typically comprise a connector and a mating connector that can be plugged together. Connectors for high-current applications (e.g., for electrical currents of more than 10A, preferably more than 50A or even more than 100A), e.g., for electric vehicles or automotive applications, often comprise contact elements with spring lamellae, e.g., toroidal or sleeve-shaped lamella cages, which are connected to a (e.g., shielded) cable by means of a mechanical crimp connection or ultrasonic welding. In other cases, the lamella cages can also be attached directly to a carrier element, e.g., a printed circuit board, e.g., soldered or by means of a press-fit contact. Such connectors are designed to be connected to a mating connector, which can, for example, comprise a contacting part, e.g., in the form of a contact pin or a contact blade or the like.The connector can, for example, be mated with the mating connector along a plug-in direction or a plug-in direction. In the final state, a contact element of the mating connector (also referred to as the mating contact element) makes electrical contact with the contact element of the connector. The spring blades of the contact element of the connector should, in the final mated state, exhibit a normal force (or contact normal force), which ensures that an electrical connection to the mating contact element is guaranteed even under mechanical and / or thermal loads and across all manufacturing tolerances. This normal force is, however, usually limited, since the mating forces when connecting the connector with the mating connector should not exceed a defined level. In order to reduce the high mating forces for an operator, for example,Lever designs or slider designs can be provided so that the operating force during mating is reduced. However, such lever or slider designs are often complex and expensive and require a large amount of movement for operation. They do not prevent damage to the surfaces rubbing against each other when the contact element of the mating connector slides along the contact blades. It is possible to reduce the mating forces by applying a friction-reducing coating to at least one contact partner (contact element and / or mating contact element) and also to reduce damage to the surfaces during the mating process. However, this increases the costs and complexity of the manufacturing process for the corresponding contact partner and does not reliably prevent damage to the surfaces of the contact partners. In addition, this can sometimes increase the contact resistance in the area of ​​the contact point.

[0008] In other applications, the contact partners (contact element and mating contact element) can be designed as busbars, for example. These can be screwed together, for example, to ensure permanent contact. When screwed together using M4 screws, for example, a so-called contact force or normal force in the range of 2000 N to 2500 N can be achieved. If M5 or M6 screws are used, even higher normal forces can be achieved. However, screwing the contact partners in this way requires additional space for arranging the screws and the means to tighten or loosen the screws during maintenance.In addition, several additional steps are necessary before and / or after the contact partners are mated together, which make the assembly process complex: the contact partners must be precisely aligned to each other in order to tighten the screw, the screw must be placed, a tool for tightening the screw must be placed, the screw must be tightened, the tool must be removed.

[0009] DE 10 2018 202 960 A1 discloses a connector for automotive applications and / or high-current applications in which the contact element is designed as a lamella cage. To reduce the high mating forces (between the contact element and the mating contact element) that occur during mating, a lever element is provided that is actuated during the mating process when the connector and mating connector are mated.

[0010] From DE 10 2017 213 093 A1 a plug contact for high current applications is known, wherein the contact element is designed as a lamella cage and in which a high insertion force (between contact element and mating contact element) must be overcome during the insertion of a mating contact element into the contact element.

[0011] From DE 10 2019 131 791 A1 a contact element of a connector is known, wherein the contact element is directly connected to a printed circuit board and wherein the contact element can be contacted by inserting a pin-like contact element of a mating connector.

[0012] From DE 20 2008 005 394 Ul a high-current printed circuit board connector with a lamella cage is known, wherein the connector can be pressed into a printed circuit board by means of a plug-in base and can thus be electrically contacted.

[0013] From WO 2007 / 107 208 A1 a plug connection of the Radsok type (Radsok connector) is known with a socket of the Radsok type (Radsok socket) and a plug that can be inserted into the socket, which form a plug-in connector arrangement when plugged together, wherein locking means are formed on the Radsok socket and the plug, which enable a defined fixing of the Radsok socket and plug.

[0014] Disclosure of the invention

[0015] The invention is based on the recognition that if a low normal force is present (at the contact point(s) between the contact element and the mating contact element) in the event of high temperature fluctuations and / or strong vibration or shaking loads, there is a risk of undesired relative movements between the contact partners (contact element and mating contact element) and / or contact interruptions. The invention is also based on the recognition that the largest possible contact area between the contact partners is advisable for a long service life of the contact and / or for low heating of the contact point when transmitting high currents. Furthermore, the invention is based on the recognition that high insertion forces over a large portion of the path when mating the connector and mating connector complicate the mating process.Furthermore, the invention is based on the knowledge that the application of the normal force between the contact element and the mating contact element, in particular when these are a socket contact (female contact element) and a contact pin or contact blade (male mating contact element), already during the plugging process - i.e. on the path or a large part of the path, e.g. more than 30% of the path, e.g. from a pre-plugging position via an intermediate plugging position (first position) to a final plugging position (second position) - not only complicates and makes the plugging process more difficult, in particular when several plug connectors are plugged together with several mating connectors at the same time, but that the surfaces of the respective contact partners can also be damaged. For example, if the normal force is applied during the plugging process, a contact blade can leave a grinding mark or a scratch on a contact part to be contacted.This can undesirably damage or destroy a surface coating and can be detrimental to repeated mating and unmating, as such scratches or grooves can cause the contact partner to jam during the mating or unmating process. A high mating force (between the contact partners) can even undesirably reduce the number of contact partners in a connector, as with a high number of contact partners, the mating forces can become so high, even when lever or slide designs are used, that the operating force is no longer reasonable for an operator. Furthermore, the invention is based on the finding that the coating of the contact partners can reduce the current-carrying capacity and increase costs.Finally, the invention is based on the realization that laminar cages that are firmly connected, in particular by means of a material bond or pressed into a chamber, to or in or on the connector can result in a defective laminar cage leading to total economic loss of the connector, since the laminar cage cannot be replaced at a reasonable cost. This compromises sustainability.

[0016] There may therefore be a need to provide a connector arrangement which enables the connection or mating of a connector with a mating connector (which may also be designed as a male connector or the like, for example) with the lowest possible mating force, which at the same time has a high normal force between the contact partners in the electrically contacted state, which has a high current carrying capacity, which provides the largest possible contact surface between the contact partners, which enables permanent, safe, reliable and uninterrupted electrical contact between the connector and mating connector even under alternating thermal loads and / or mechanical loads such as vibration loads or shaking loads, which requires only a small installation space orAssembly space requires, which enables safe operation (no risk of contact with live parts), in which at least the contact partners (contact element and counter contact element) can be manufactured cost-effectively and easily, in which the establishment of the contact with the desired normal force is possible in a simple manner with as few steps as possible and even in complicated installation space situations and which can be repaired in a simple manner, so that a sustainable product is provided.

[0017] Similarly, there may be a need to provide a connector having the properties described above.

[0018] Advantages of the invention

[0019] This need can be met by the subject matter of the present invention according to the independent claims. Advantageous embodiments of the present invention are described in the dependent claims.

[0020] According to a first aspect of the invention, a connector arrangement is proposed, in particular for high-current applications and / or high-voltage applications, in particular for automotive applications, in particular for electric vehicles (which may include, for example, fully or partially electrically powered aircraft, ships, boats, e-bikes, motorcycles).

[0021] The connector assembly comprises a connector and a mating connector for mating with the connector. The connector comprises a lamella cage having a base element and a plurality of contact lamellas. The contact lamellas are connected to the base element in a rear section; they protrude from the base element in the direction of the mating connector. The contact lamellas have a front section that faces the mating connector and has a cantilevered end or through which the contact lamellas are connected to a head element of the lamella cage (in this alternative, the contact lamellas are connected to the head element by means of the front section). The contact lamellas have a contacting section that is arranged between the rear section and the front section. The lamella cage has a coupling section.The connector has a contact chamber with an outer wall. The laminar cage is arranged in the contact chamber. The contacting sections are curved towards the outer wall with respect to the rear section and the front section, in particular, for example, in the force-free state. The mating connector has a contact element with an underside facing the laminar cage. The contact element and / or the mating connector is / or can be moved between a first position and a second position, in particular along a plug-in direction, in particular when plugged together with the connector. At least up to the first position, the contact element and / or the mating connector can be moved along the plug-in direction with a force of less than 5N, in particular without applying any force.In the second position, the contact element mechanically contacts the coupling section of the laminar cage in such a way that the contacting sections of the contact laminations are displaced towards the outer wall, in particular along a radial direction, and the contacting sections thereby electrically contact a contact section of the outer wall.

[0022] This advantageously ensures that the laminar cage can be mounted particularly easily and reliably in or on the connector and can also be removed again. It can, for example, be plugged or pushed into the contact chamber. This means that it is automatically positioned in the correct position in the connector. Another advantage is that a particularly large electrical transition area can be formed from the laminar cage to the connector by means of the defined contacts of the majority of the contact laminations on the contact section of the outer wall, which reduces the contact resistance. This is also possible when the laminar cage is not pressed particularly tightly against the contact chamber in the first position or directly after assembly, or even when the laminar cage is loosely arranged in the contact chamber. Furthermore, for examplean additional electrical conduction path can be formed at least in the second position in that a bottom of the contact chamber is electrically contacted with the base element when the lamellar cage is pressed against the bottom of the contact chamber by the force applied by the contact element. In this way, a complex press-in assembly, e.g. into a circuit board or soldering or welding of the lamellar cage, e.g. to a carrier substrate or an electrical component, can be dispensed with, or even a complex press-in assembly or the like in a contact chamber. The electrical contact between the lamellar cage and contact element (and thus between the connector and the mating connector) can be brought about, for example, by the mechanical contact between the coupling element and the contact element. This can be achieved, for example, by an axial force acting on the coupling area, e.g. through an underside of the contact element.In this way, a high contact normal force can advantageously be achieved between the contact element and the coupling area or coupling section, without the contact element and the coupling area or coupling section having to cover a longer axial friction distance relative to each other, which could damage the surfaces of the contact partners.

[0023] It can be provided, for example, that the outer wall of the contact chamber rests loosely on the contacting sections of the contact blades when the laminated cage is in the force-free state or is preferably spaced from the base element by a (radial) gap, e.g. by a gap of at most 500 μm, preferably of at most 200 μm and particularly preferably of at most 100 μm. In this way, the laminated cage can on the one hand still be easily inserted into the contact chamber, ideally without force. At the same time, however, it is positioned very precisely with regard to the radial direction, which ensures a simple and reliable joining process with the mating connector and also leads to radial contact between the contacting sections and the contact section even with a small axial compression path, in particular with a high contact normal force. This results in a high possible path-force ratio.

[0024] Another advantageous effect is that the joining or mating of the plug connector and mating connector can be carried out largely force-free or with a very low insertion force, and the actual application of the normal contact force to the contact element of the mating connector only occurs at the end of the mating process. In contrast to conventional lamella cages, in which the insertion process of a male mating contact element of the mating connector already has to widen the contact blades radially outwards (so-called "beak-opening peak" in the insertion force) and the friction force between the contact blades and contact element also has to be overcome on the further path, according to the invention an increased force needs to be applied only at the end of the insertion process or the joining process, which is necessary so that the contact blades radially outwards or inwards.be shifted radially towards the outer wall (in particular by axial compression) and can thus apply the normal contact force to the contact element. This advantageously simplifies the assembly process, further advantageously enables larger manufacturing tolerances, as tilting due to the insertion forces is prevented and further advantageously enables the arrangement of the connector and mating connector to be corrected during the assembly process (at least up to the first position). Another advantage is that the joining and / or plug-in process can also be distributed across different, spatially separate machines or workstations in a production line: in a first step, the connector and mating connector are simply plugged together or joined until the first position is reached. This occurs essentially force-free or with a very low insertion force.In this first position, the contact element of the mating connector is advantageously already in loose mechanical contact with the coupling section or is only slightly spaced from it (along the insertion direction), e.g., at most 200 μm or at most 100 μm). In a second step (which can, for example, also be carried out at a different workstation or by other machines or assemblers), the normal contact force can then be applied and thus the desired electrical (and also mechanical) connection can be formed. In this way, pre-assembly is possible. It may also be possible, for example, to secure the pre-assembly process (reaching the first position), e.g., mechanically, e.g., by a type of primary locking mechanism, so that the pre-assembled connector assembly can be transported to another location without problems and without being lost.

[0025] Furthermore, this advantageously prevents the surfaces of a male mating contact element and contact blades from being damaged or destroyed over a longer distance during the joining process (e.g. from the beginning of the overlap between the contact blade contact point and the contact part of the contact element up to a contact section of the contact part) - as is the case with the cited prior art. This is because the axial force exerted when the blade cage is compressed primarily displaces the blades radially and not, or only very slightly, in the axial direction. This means that there is hardly any frictional movement between two surfaces along the axial direction. This also enables the connector and mating connector to be plugged together and unplugged multiple times (e.g. for repairs, maintenance, etc.), which advantageously improves the sustainability of the connector arrangement and the associated components.

[0026] Furthermore, the number of contact blades can be increased in comparison to conventional connector arrangements (with a male counter-contact element, which is inserted into the interior of a blade cage or a socket contact and must push the contact blades present there apart during the insertion path) and / or the applied normal force of the contact blades in the final plug-in position can be increased. Alternatively or additionally, a material can be used for the contact blades which has a higher spring constant or a higher modulus of elasticity. This can advantageously achieve an improved current-carrying capacity over the lifetime, the thermal load on the contact partners in the contact area can be advantageously reduced (lower contact resistance) and the connector arrangement can therefore have increased robustness, e.g.to alternating thermal loads, vibrations and / or manufacturing tolerances. An increased axial force only needs to be applied at the end of the mating process - on the (particularly short) path from the first position to the second position - in order to generate a radially acting contact normal force (between the contact blades and the outer wall). This axial force also influences, for example, the contact normal force between the blade cage and the contact element. Because of the short axial path with increased force application, an actuating element can be arranged on the connector and / or the mating connector which, despite a possibly limited operating path, has a particularly high force ratio (e.g. more than 10:1 or more than 50:1, or more than 100:1).In cases where space is limited and there is little room for the movement of such an actuating element, the proposed invention can make a significant force transmission possible using simple means. Such an operating element or actuating element—which can be provided optionally, but is not absolutely necessary and therefore not essential—can be designed, for example, as a lever or a slider. Such an actuating element can be arranged, for example, on a connector housing or on a mating connector housing.

[0027] It may, for example, have a link structure which interacts with a complementary pin or bolt on the mating element (if the actuating element is arranged, for example, on the connector or on the connector housing, then the bolt or pin may be arranged on the mating connector or mating connector housing).

[0028] Compared to a purely axial contact system, in which the laminar cage is only axially clamped between the base of the contact chamber and the contact element, the number of contact points between the laminar cage and the contact chamber is advantageously increased. This advantageously increases the current-carrying capacity, reduces the electrical contact resistance, increases the redundancy of the contact points, reduces the thermal stress on the contact point, and also further improves robustness against manufacturing tolerances and vibrations and / or shaking loads. This is because the contacts between the base element and the base of the contact chamber are formed along the axial direction and are thus orthogonal to the contact points between the contact laminations and the outer wall, which preferably act or are formed in the radial direction.

[0029] The insertion direction can be defined, for example, as the direction along which the mating connector is mated with the connector. It can preferably be defined, for example, as the direction along which the contact element is displaced relative to the laminar cage to establish contact. The insertion direction can also be referred to, for example, as the axial direction.

[0030] The radial direction, for example, runs perpendicular to the insertion direction. A circumferential direction, for example, runs around the insertion direction.

[0031] The contact lamellas can, for example, be curved with their contacting sections in the radial direction towards the outer wall or in the direction of the outer wall.

[0032] In the second position, the contacting sections of the contact blades, in conjunction with the contact section of the outer wall, can clamp the blade cage, for example, between the outer wall. This advantageously ensures that a blade cage that is initially loosely inserted into the contact chamber, for example, has a secure and permanent contact with the contact chamber in the final contacted state (second position). If the contact element is moved back to the first position or even further back, for example through an elastically reversible design of the contact blades, the blade cage can again sit or be arranged loosely in the contact chamber and can thus be easily replaced, for example for repair or maintenance.

[0033] Contacting the coupling section can be achieved, for example, through an underside of the contact element facing the coupling section. This underside can be substantially planar, level, or flat. The contacting or mechanical force exerted by the contact element on the coupling section can, for example, be substantially along the axial direction or the insertion direction.

[0034] The coupling section can be formed, for example, by the front section or by the head element. The protrusion of the contacting section(s) can be understood to mean that, viewed in the radial direction in the force-free state, the contacting section is less spaced from the outer wall (or is closer to the outer wall) than the front section and / or the rear section. This can advantageously have the effect that, in a simple manner - without further material influences such as targeted weakening or strengthening of the material or thermal, chemical or other treatments - an axial compression of the laminar cage leads to a displacement of the contact laminations in the contacting area even closer to the outer wall and ultimately to contact. In other words: the application of axial force then leads to an even further protrusion towards the outer wall.The contact lamellae therefore have a well-defined preferred direction for displacement when subjected to axial force or axial compression.

[0035] The contact element can, for example, cover the coupling section in the radial direction or protrude beyond the coupling section, e.g., by at least 500 μm, particularly preferably by at least 1 mm. It can, for example, completely cover the coupling section. This advantageously ensures particularly reliable mechanical contact during displacement from the first to the second position and in the second position. Furthermore, positioning tolerances in the radial direction are advantageously unproblematic.

[0036] For example, in contrast to conventional contact elements which are plugged into the interior of the laminar cage as male contact elements, the contact element may not have a contact part protruding from a head section of the contact element. Instead, the underside may be designed without such a contact part, for example. The contact element may, for example, be essentially flat on the underside in a side view. In other embodiments, however, it may also have a centering part which protrudes from the underside like a male contact part. Such a centering part can, for example, serve to guide the contact element into the correct (radial) position relative to the laminar cage when plugging together. It can, for example, be threaded into the interior of the laminar cage and thus center the contact element in the radial direction. Furthermore, the guidance of the contact element can be simplified as a result (compared to a contact element with a flat orflat underside), so that tilting during mating, especially when moving from the first position to the second position, is prevented. Such a centering part can, for example, be formed integrally with the head section of the contact element. However, it can also be made of a different material, e.g., an insulating material, and / or be subsequently coupled or connected to the head section to form a unit that is then formed.

[0037] Such a centering part can, for example, protrude at least 2 mm from the contact element or a head section of the contact element, preferably at least 5 mm and particularly preferably at least 10 mm.

[0038] The lamella cage can, for example, be designed so that the contact element with such a centering part can be inserted into an interior of the lamella cage.

[0039] The base element and / or an optionally present head element of the laminar cage can, for example, also be referred to as a collar or, for example, be designed as a collar to which the contact laminations are fastened. The base element and contact laminations or the head element and contact laminations can, for example, be manufactured in one piece, e.g. from a single piece of sheet metal. They can, for example, be designed as a stamped and bent part. The contact laminations can, for example, be designed to contact the contact section, in particular to contact it electrically. If a head element is provided, the head element can, for example, be designed or serve or act as a coupling section. It can then, for example, protrude furthest in the direction of the contact element or form a type of end face of the laminar cage with respect to the contact element. In this configuration, the head element can, even in the event of an unevenly acting force from the contact element (e.g.This evens out the force distribution across the individual contact segments (e.g., if the contact segment is tilted). This also applies to established contacting, where, for example, vibrations lead to a changing force distribution along the head section. This ensures particularly reliable and uniform contact of the contact section of the outer wall with a well-defined contact normal force.

[0040] The contact blades can, for example, have a self-supporting or free end in the front section or be self-supporting in the front section. It can, for example, be provided that the contact blades are not connected to one another in the front section. Such a free end can, for example, point directly in the direction of the mating connector and thus represent a type of end face of the contact blade in the direction of the contact element. However, there can also be embodiments in which the contact blades are bent at or with their free end and, for example, point in a radial direction (radially inwards or radially outwards) or even point in the direction of the base element. In such a case, part of the front section forms the end face that projects furthest from the base element in the direction of the contact element. This end face or the front section or the free ends can represent the coupling section in this configuration.This can advantageously result in a particularly high number of contact points between the lamella cage and the contact element.

[0041] The displacement between the first position and the second position can occur, for example, along the insertion direction. The first position can be, for example, an intermediate insertion position in which a large portion (e.g., more than 70%, preferably more than 90%) of the insertion path between the connector and the mating connector has already been completed. The second position can be, for example, a final insertion position.

[0042] In the first position, for example, a gap can be formed between the contact sections and the outer wall (with simultaneous overlap of the contact sections and the outer wall). This gap can, for example, allow for radial play between the contact chamber or outer wall and the contact lamellae or lamella cage. This allows for easy installation or removal of the lamella cage.

[0043] In the second position, the contact lamellae, in cooperation with the outer wall, can clamp the lamella cage, for example, between the outer wall. The clamping can be formed, for example, along the radial direction. The term "clamping" here means that the lamella cage - assuming that the contact element remains unchanged on the coupling section in the second position - is held or clamped in the contact chamber by the contact lamellae in a captive manner. The lamella cage is thus clamped or clamped, viewed along the radial direction, between the outer wall or inside the contact chamber. In other words: in the second position, the lamella cage has an excess dimension with respect to the contact chamber in relation to the space defined by the outer wall (with only two contact lamellas that were approximately opposite each other, the excess dimension could, for example,regarding the distance between the contact blades).

[0044] For example, it can be provided that the contact plates and the outer wall enclose a contact space between them. In other words, the contact space can be formed radially outside the contact plates, for example. It can be part of an outer space of the laminar cage, for example.

[0045] For example, when not fully assembled (i.e., during the insertion or joining process up to the first position), the contact chamber may exhibit an oversize (particularly along the radial direction) relative to the laminar cage. When fully assembled, particularly in the second position, the laminar cage may exhibit an oversize (particularly along the radial direction) relative to the contact chamber.

[0046] The term "force-free" is to be understood as meaning that joining or mating the connector and mating connector, at least up to the first position, requires only a negligible amount of force or mating force, and in particular, no peeling peak for pushing apart the contact blades or frictional force between the contact partners must be overcome. Particularly for power contacts for high-current or high-voltage applications, a joining or mating force of less than 10 N, preferably less than 5 N, and particularly preferably less than 3 N can be considered "force-free."

[0047] The contact blades can, for example, be designed to be elastically reversible. This means that when the contact element returns from the second position to the first position, the contact blades return to their original position (i.e., they move radially away from the outer wall). This advantageously allows unplugging or disassembling without significant unplugging force and / or without damaging the surfaces of the contact partners (outer wall to contact blades, but also, for example, the coupling section to the contact element). Furthermore, a renewed plugging or joining process is then possible (almost) force-free, at least up to the first position.

[0048] It can be provided, for example—particularly in the case of contact blades arranged opposite one another—that the contact element mechanically contacts the coupling section in such a way that the contact blades, in particular their contacting section, are displaced radially outward on the path of the mating connector or, in particular, the contact element from the first position to the second position, and the contacting sections thereby electrically contact the contact section of the outer wall. In the second position, the contact blades or their contacting sections are then displaced radially outward or radially toward the outer wall, and thus contact the contact section.

[0049] On the way from the first position to the second position and in the second position, the contact element can, for example, be in axial contact with the coupling section of the laminar cage, thereby exerting an axial force on the laminar cage and in particular on the contact laminations, which leads to at least partial displacement of the contact laminations in the radial direction toward the outer wall. In the second position, the contact element can be pressed onto the coupling section, in particular along the axial direction.

[0050] The contact element can, for example, be designed in one piece. For example, in the case where a contact element is provided with a head section and a centering element or centering part projecting therefrom in the direction of the laminar cage, the centering part and the head section can be designed so that they cannot be separated from one another without causing damage. It can, for example, be provided that the head section and the centering part are rigidly connected to one another, in particular not displaceable relative to one another. Alternatively, it can be provided that the head section is displaceable relative to the centering part, e.g. along the axis of the centering part. For example, the centering part can be movable through an opening in the head section. The centering part and head section can, for example, be formed from an electrically conductive material, e.g. from the same material. In an alternative embodiment, the head section and / or an underside of the head section can, for example,be made of a different material than the centering part, e.g. the centering part can be made of an insulating material, wherein the centering part is designed or arranged or serves only for the radial positioning of the contact element relative to the laminar cage.

[0051] The contact element or the head section or the underside can, for example, be designed to be electrically conductive, in particular in those areas which are mechanically in contact with the coupling section in the second position.

[0052] An optional centering part can, for example, have a diameter in the range between 2 mm and 30 mm, preferably between 4 mm and 20 mm. An individual contact lamella can, for example, have a thickness in the range of 200 μm (200 micrometers) to 3 mm, preferably between 400 μm and 2 mm. A lamella width or the width of a lamella can, for example, be greater than the thickness of the contact lamella.

[0053] For example, it can be provided that the diameter of the outer wall of the contact chamber is at least 20um larger than a diameter of the laminar cage, preferably at least 50um.

[0054] The term “comprise” is used synonymously with the term “have” unless otherwise stated.

[0055] In a further development, it is provided that in the second position the contact blades each contact the contact section with a contact normal force in the radial direction of at least 1 N, preferably of at least 5 N. For example, the contact normal force of the contact blades, in particular of each contact blade or of the majority of contact blades, is in a range between 5 N and 50 N or even between 5 N and 200 N. This advantageously results in particularly safe and reliable contact which has a low contact resistance over its service life, even in the event of vibrations, under alternating thermal loads or other operating conditions. This advantageously makes it possible to keep heating at the transition between the contact partners to a minimum, even at high currents of, for example, more than 50 A or even more than 100 A.This also advantageously reduces installation space, weight, and material usage in the contact zone, especially in the laminar cage, since reliable contacting using high contact normal force allows for a small number of contact points. This also advantageously increases the service life of the connector assembly.

[0056] In a further development, it is provided that the base element and / or the head element of the laminar cage is designed to be closed all the way around. This advantageously ensures that the laminar cage is designed to be particularly stable and that the contact laminations cannot spread the base element apart in the second position. This advantageously ensures particularly reliable and long-lasting application of the contact normal force. A closed head element advantageously provides stabilization in the same way. It is also prevented that the head element spreads open when mechanically contacted by the contact element, thereby preventing contact with the contact part from being lost in sections or completely. For example, it can be provided that the base element and / or the head element or the collar (the further collar) or the collar area (or the further collar area) of the laminar cage is designed to be annularly closed.

[0057] The base area and / or the head element can, for example, have a circular or elliptical cross-section in the force-free state (i.e., before the mating connector is mounted). However, a polygonal cross-section, e.g., triangular, square, pentagonal, hexagonal, heptagonal, or octagonal, of the base element and / or the head element is also conceivable. Even more than eight corners are conceivable.

[0058] The circumferentially closed shape can be brought about, for example, by rolling up an originally flat stamped and bent part, e.g. made from a metal sheet. In order to keep the base region and / or the head element closed, a material-to-material connection (e.g. by a welding process, an adhesive process, or a soldering process) can be provided. However, a form-fitting connection can also be provided, e.g. at one end of the base region and / or the head element at least one type of eyelet or a type of recess with a neck region with a flat or narrow neck can be formed, and at the other end of the base region and / or the head element at least one type of tenon with a shape complementary to the eyelet or the recess (tongue and groove principle). After the stamped and bent part has been rolled up, the at least one tenon can then be inserted into the complementary at least one associated eyelet orA recess is inserted so that the base element and / or the head element cannot unroll again. A positive connection allows for a particularly simple and cost-effective assembly and temperature-stable connection.

[0059] In a further development, it is provided that the first position and the second position are located apart by a maximum of 5 mm along the insertion direction, preferably by a maximum of 2 mm and particularly preferably by a maximum of 1 mm. This advantageously ensures that the contact partners (contact blades, in particular their contacting sections and outer wall, in particular their contact section; possibly also the coupling section and contact element or its underside) can only rub against each other along a very short, in particular axial, path, and damage to the surfaces is thereby prevented or limited to a very short path range. Furthermore, this advantageously makes it possible to provide a connector arrangement that requires only an extremely small installation space along the insertion direction. Finally, in this way, a particularly high normal force can be applied, for example whenan actuating element is provided to reduce the operating force. If, for example, the travel between the first position and the second position is 1 mm and the travel of an optional actuating element, such as a slide element or a rotatably mounted lever element, is 100 mm, then a force transmission ratio of 100:1 can be achieved. The entire travel of the actuating element and thus the entire force transmission can thus be used to apply the contact normal force. It is not necessary to waste part of the actuating travel for part of the joining travel. Another advantage is that the force transmission can be very uniform along the actuating travel, e.g. by means of an essentially linear link path with a uniform gradient in the actuating element.This is because an optional actuating element only needs to be used for the distance from the first position to the second position, not for the entire joining path. Alternatively, the actuating path can be reduced while maintaining the same force transmission, saving installation space or free space for the actuating element.

[0060] In a further development, the radial play between the contacting section and the outer wall is in a range between 5 µm (5 micrometers) and 200 µm (200 micrometers), or in a range between 20 µm and 100 µm. This has the advantageous effect that a high contact normal force can be generated even with a short distance between the first position and the second position. A high force transmission can also be achieved in this way, as only a very short radial path has to be covered for contacting or only a very small gap has to be closed. If, for example, an axial path of 1 mm is available between the first and second positions and the gap or the radial play is uniformly 100 µm all around, then a force transmission of 10:1 is already achievable. At the same time, even such a small radial play advantageously makes the insertion or removal process easier.This allows for virtually force-free joining, at least up to the first position. Such minimal play also enables a particularly compact design of the laminar cage and / or the connector in the radial direction. A further development provides for a groove with an inner wall, a base, and an outer wall to be incorporated into the underside of the contact element to accommodate the coupling section.

[0061] This advantageously ensures that the coupling section or the head element or the contact blades (in particular with their front section or the part of the contact blade that projects furthest from the base element in the direction of the contact element (with their front side)) can be received or arranged in the groove, and are arranged or received in the groove in particular in the second position. This capturing of the coupling element or the head element or the contact blades can, for example, already take place in the first position of the contact element. This in turn advantageously ensures that during the (further) displacement of the contact element from the first position to the second position, the coupling section or the head element or the front sections of the contact blades are always in a defined position and the pressing process of the contact blades in the radial direction against the outer wall takes place in a particularly defined and reliable manner.At the same time, tilting or jamming of the contact element or its head portion when moving from the first position to the second position is prevented, which could, for example, be caused without the groove by individual contact blades whose front sections could be radially misplaced due to manufacturing tolerances, etc. The groove thus captures the front sections and then enables the correct establishment of the plug connection in the contact section when moving to the second position.

[0062] Furthermore, such a groove can advantageously increase the contact area between the coupling section and the contact element, and thus between the laminar cage and the contact element, particularly compared to an embodiment in which contact is only made on a flat underside. This is because by moving the contact element into the second position, the part of the coupling section or the head element or the contact laminations trapped in the groove can ultimately only expand in the radial direction, since the axial space available to the contact lamination is reduced. This expansion in the groove leads to a greater filling of the groove with parts or material of the contact lamination and thus to a larger contact area (the groove has an inner groove wall, a groove base, and a groove outer wall).Furthermore, by filling the groove more with contact lamella material, the force of the contact lamella in the groove on the groove walls and groove base is increased, which increases the normal contact force of the coupling section or the head element or the contact lamellas to the boundary surfaces of the groove (groove walls and groove base). This advantageously creates additional contact paths in the groove, which increases the redundancy of the contact points, reduces the contact resistance and advantageously increases the reliability and service life of the connector arrangement and in particular of the contact point. Alternatively or additionally, the groove can clamp the coupling section or the head element or the contact lamellas in the radial direction (between the inner wall and the outer wall of the groove) and thus create lateral contact surfaces. This can be successful in particular if the groove is designed to be narrow enough, at least in sections, that it can, for example,Contact lamellas have an excess with regard to a distance between the inner wall of the groove and the outer wall of the groove.

[0063] The groove can, for example, be circumferential. It can, for example, be closed, in particular, closed all the way around. It can, for example, have the same cross-section throughout.

[0064] If a centering element is present, the groove can be located, for example, between the centering element and an edge of the underside. It can, for example, run around the centering element in the circumferential direction.

[0065] This advantageously increases the number of contact points between the laminar cage and the contact element, reduces the contact resistance and improves the robustness against vibrations, thermal loads and manufacturing tolerances.

[0066] It can be provided, for example, that the coupling section or the head element or the contact blades contact the groove, in particular on at least two sides. This advantageously further increases the contact surface or the contact points between the blade cage and the contact element. This increases robustness against adverse operating conditions and reduces contact resistance. As already described above, the groove has three surfaces or sides: an inner groove wall or groove inner side (which, for example, in the case of a groove that runs in the circumferential direction in the contact element, encloses an inner region and / or, for example, runs around an optionally provided centering part), a groove outer wall or groove outer side (which, for example, is formed radially outside the inner groove wall and, for example, runs closer to an edge of the contact element or its head section or is closer to the outer wall of the contact chamber than the groove inner side), and a groove bottom or a bottom side.The groove base can, for example, extend transversely to the insertion direction.

[0067] For example, it can be provided that the surfaces or sides of the groove contacted by the front section are rotated relative to each other by at least 30°. Thus, in the second position, for example, the groove bottom and the groove inner wall can be contacted by the coupling section or the head element or the contact blades or their front section, or the groove bottom and the groove outer wall, or all three walls can be contacted by the coupling section or the head element or the contact blades.

[0068] In a further development, it is provided that in the second position the mechanical contact of the coupling section is made through the groove base.

[0069] In other words: it is provided that in the second position, the contact element with the groove bottom mechanically contacts the coupling section in such a way that the contacting sections of the contact lamellas are displaced along the radial direction towards the outer wall and thereby electrically contact a contact section of the outer wall and in particular clamp the lamella cage between the outer wall.

[0070] In other words, the groove base exerts a force acting primarily in the axial direction on the coupling section or on its end face. This compresses the contact blades in the axial direction and causes them to deflect radially in the contacting section toward the outer wall. As a result, the contact section of the outer wall is mechanically and electrically contacted by the contacting sections of the contact blades, and a defined contact normal force is applied by the contact blades to an inner side of the outer wall.

[0071] This advantageously results in a particularly defined position of the mechanical contact of the coupling section.

[0072] Furthermore, this advantageously creates axial contact between the laminar cage and the contact element, which is particularly robust against vibrations, thermal expansion, manufacturing tolerances, etc., which act in the radial direction. In a further development, it is provided that an inner groove wall, in particular facing away from an outer edge of the underside, runs diagonally outward toward a groove bottom.

[0073] In other words: the groove has - when viewed from the underside - a funnel-shaped slope on the inside of the groove further away from the edge or further away from the outer wall of the contact chamber.

[0074] This has the advantageous effect that the contact blades (in particular their contacting section) are not displaced in a radial direction solely due to the axial force exerted by the contact element on the front section. Rather, the bevel can act as a type of slotted guide, by means of which the coupling section is specifically moved or displaced in the radial direction towards the outer wall. In this way, the displacement can be influenced in a targeted or more targeted manner. Furthermore, the shape of the bevel can advantageously form a type of path-force curve, by means of which the translation of the axial path of the contact element into a radial path of the contact blades can be adjusted when the contact element is displaced from the first position to the second position.By adjusting the inclination, the application of the normal force can be advantageously adapted to the given installation space situation and the available path from the first position to the second position.

[0075] In particular, the groove can run obliquely on the inner wall of the groove in such a way that a kind of (half-)funnel shape can be seen when looking into the groove.

[0076] For example, a first angle of the groove inner wall with respect to the insertion direction can be in a range between 2° and 45° or in a range between 3° and 15°.

[0077] In a further development, it is provided that the groove has a funnel shape in cross section.

[0078] In other words, the inner and outer walls of the groove both run diagonally and taper into the contact element. For example, the groove can be shaped like an inverted "V" or a "Y," with the more open side of this shape facing the coupling section.

[0079] This advantageously ensures that the coupling section, the head element, or the contact blades can be securely threaded into the groove, even with positioning and / or manufacturing tolerances. This advantageously increases manufacturing reliability when mating the connector and mating connector.

[0080] Another advantage is that this results in a larger contact surface and a higher number of contact points between the laminar cage and the contact element. If, for example, the coupling section or the head element or the contact laminations are too wide for the funnel width at this point at the narrow point of the funnel, the coupling section or the head element or the contact laminations are clamped in laterally and thus contacted. Here, too, the funnel shape offers an advantage in terms of manufacturing tolerances. If, for example, the coupling section is too wide, insertion into the groove is not blocked or lead to damage to the groove and / or coupling section. Instead, the coupling section is inserted into the funnel-shaped groove until it reaches an excess size in relation to the funnel shape and is clamped in place.A further axial displacement of the contact element is converted into a further compression of the contact blades in the contact area and then increases the normal force there.

[0081] This ensures particularly high manufacturing reliability as well as particularly safe and reliable contact between the laminar cage and the contact element.

[0082] In a further development, it is provided that in the second position the coupling section is clamped between the groove inner wall and the groove outer wall, so that the coupling section electrically contacts both the groove inner wall and the groove outer wall.

[0083] This advantageously creates a particularly large contact area between the laminar cage and the contact element. Furthermore, this advantageously makes the contact particularly robust against, for example, mechanical or thermal influences and / or manufacturing tolerances in the axial and radial directions. According to a further aspect of the invention, a connector is proposed, in particular for high-current and / or high-voltage applications.

[0084] The connector is suitable or configured for mating with a mating connector having a contact element. The connector has a lamella cage with a base element and a plurality of contact lamellas. The contact lamellas are connected to the base element in a rear section and protrude from the base element in the direction of the mating connector. The contact lamellas have a front section that faces the mating connector and has a cantilevered end or through which the contact lamellas are connected to a head element of the lamella cage. The contact lamellas have a contacting section that is arranged between the rear section and the front section. The lamella cage has a coupling section, wherein the coupling section can be formed, for example, by the front section or by the head element.The connector has a contact chamber with an outer wall. The laminar cage is arranged in the contact chamber. The contacting sections are curved (e.g., radially) toward the outer wall relative to the rear and front sections, particularly in the force-free state.

[0085] The lamella cage is designed such that when a force is applied along a plug-in direction to the coupling section (e.g. by a contact element of the mating connector) or by a displacement of the coupling section along the plug-in direction, which corresponds e.g. to a displacement of the contact element and / or the mating connector from the first position to the second position, the contacting sections of the contact lamellas are displaced along a radial direction towards the outer wall and the contacting sections thereby electrically contact a contact section of the outer wall and in particular clamp the lamella cage between the outer wall.

[0086] This results in the same advantages as described above for the connector arrangement.

[0087] Drawings Further features and advantages of the present invention will become apparent to those skilled in the art from the following description of exemplary embodiments, which, however, are not to be construed as limiting the invention, with reference to the accompanying drawings.

[0088] They show:

[0089] Fig. 1: a schematic perspective view of a connector arrangement in a non-contacted state;

[0090] Figs. 2a to 2c: perspective schematic views of two different laminar cages of a connector (Figs. 2a and 2b) and a plan view of a stamped sheet (Fig. 2c) as the initial state for a laminar cage;

[0091] Figs. 3a and 3b: schematic cross-sections through a connector arrangement with the mating connector in a first position (Fig. 3a) and in a second position (Fig. 3b), respectively;

[0092] Figs. 4a and 4b: schematic cross-sections through two further connector arrangements with the mating connector in the second position;

[0093] Figs. 5a and 5b: schematic cross sections through a further connector arrangement with the mating connector in the first position (Fig. 5a) and in the second position (Fig. 5b), respectively.

[0094] Figure 1 shows a schematic perspective view of a connector assembly 100 in a non-contacted state, e.g., in a pre-mating position. For reasons of clarity, neither an actuating element (such as a lever element or a slide element) for reducing the operating force during mating, nor a connector housing or a mating connector housing are shown here. Such elements are known from the prior art and do not represent essential elements for the implementation of the invention.

[0095] The connector assembly 100 is configured here merely by way of example for high-current applications (e.g. for transmitting at least 10A, preferably at least 50A and particularly preferably at least 100A) and / or high-voltage applications (e.g. for at least 100V, preferably at least 200V and particularly preferably at least 500V).

[0096] The connector assembly 100 comprises a connector 1 and a mating connector 2 for mating, here, for example, in particular along a mating direction E, with the connector 1, wherein a radial direction R runs perpendicular to the mating direction E and wherein a circumferential direction U encircles the mating direction E. The mating direction E can also be referred to as the axial direction. In other cases, it can also be defined as the displacement direction of a contact element 9 (described below) with respect to a laminar cage 3 (described below) during the contacting process.

[0097] The connector 1 has a lamella cage 3 with a base element 4 and a plurality of contact lamellas 5. The contact lamellas 5 are connected to the base element 4 in a rear section 6. They protrude from the base element 4 in the direction of the mating connector 2 and have a front section 7, which faces the mating connector 2 and through which - here by way of example - the contact lamellas 5 are connected to a head element 40 of the lamella cage. In other embodiments, the contact lamellas 5 can, for example, have a self-supporting end 8 in the front section 6. The contact lamellas 5 further have a contacting section 41, which is arranged between the rear section 6 and the front section 7.

[0098] Furthermore, the laminar cage 3 has a coupling section 42. This is formed here merely by the head element 40, for example. In other embodiments, it can be formed, for example, by the front section 7. The connector 1 further has a contact chamber 14 with an outer wall 15, wherein the laminar cage 3 is arranged in the contact chamber 14. The contacting sections 41 are curved (here, for example: radially) in the direction of the outer wall 15, particularly with respect to the rear section 6 and the front section 7.

[0099] The mating connector 2 has a contact element 9 with an underside 35 facing the laminar cage 3. The mating connector 2 and / or the contact element 9 is / are, in particular when plugged together with the connector 1, displaceable between a first position PI and a second position P2 (see Figs. 3a, 3b, 4a, 4b, 5a, 5b), in particular along the insertion direction E. At least up to the first position PI (see Figs. 3a, 5a), the mating connector 2 and / or the contact element 9 can be displaced along the insertion direction E with a force of less than 5N, in particular force-free. In the second position P2 (see Figs.3b, 4a, 4b, 5b), the contact element 9 mechanically contacts the coupling section 42 of the laminar cage 3 such that the contact sections 41 of the contact laminations 5 are displaced along the radial direction R toward the outer wall 15, and the contact sections 41 thereby electrically contact a contact section 13 of the outer wall 15. They can, for example, clamp the laminar cage 3 between the outer wall 15.

[0100] The first position PI can be referred to, for example, as the pre-contact position or intermediate plug-in position - here, the contact element 9 can already be loosely in mechanical contact with the coupling element 42, e.g., resting against it or arranged very close to the coupling element 42, e.g., less than 500µm or less than 200µm. The second position P2 can be referred to, for example, as the final contact position or final plug-in position, in which the electrical connection is formed in the desired state. A position as shown in Fig. 1 can be referred to, for example, as the pre-plug-in position, in which, for example, the first position has not yet been reached.

[0101] The contact chamber 14 can, for example, be electrically connected to the first component 50. Depending on the embodiment, it can also be mechanically connected to the first component 50, e.g. by a press-in connection and / or a soldered connection or the like. The laminar cage 3 can, for example - in the first position PI - be arranged loosely in the contact chamber 14, e.g. with play or a gap 29 (see Figs. 3a, 5a) to the outer wall 15. The first component 50 can, for example, be designed as a printed circuit board 51 or as a current collecting rail or so-called "busbar". It can also be connected directly to an electrical power component, e.g. an inverter, an AC / DC converter, a battery, an electrical machine or the like, or be designed as such a power component. Thus, a particularly simple embodiment of a plug connector 1 is shown here.It is understood that in other embodiments the connector 1 may also have a connector housing in which the lamella cage 3 is arranged.

[0102] The contact element 9 here has, for example, a head element 10. It also has - purely by way of example - a centering part 11 protruding therefrom in the direction of the laminar cage 3 and having a (front) end 31, wherein the centering part 11 can be omitted in other embodiments; in this case, it is not absolutely necessary for electrical contact. The (front) end 31 of the centering part 11 is designed here merely by way of example as a self-supporting end. In this exemplary embodiment, the contact element 9 has a mushroom shape (a T-shape in longitudinal section). The centering part 11 preferably serves to radially center the contact element 9 relative to the laminar cage 3. It can also serve (see Figs. 3a, 3b) to radially stabilize the contact element 9 in the second position P2. In principle, it can be made of an insulating material.

[0103] The contact element 9 is here, for example, electrically connected to a second component 60, e.g. directly as shown here or via a line or via a busbar, etc. The second component 60 can, for example, be designed as a further power unit, e.g. as an inverter, an electrical machine, a battery, etc. However, the second component 60 can also be a printed circuit board or a line that is connected to the further power unit.

[0104] The second position P2 can be reached from the first position PI, for example, by applying an axial force to the contact element 9, in particular along the insertion direction E. The laminar cage 3 is mechanically contacted by this axial force or the axial pressure of the contact element 9 or the head part 10 or its underside 35, and the contact laminations 5 deviate under this force at least partially (in particular in the radial direction R) towards the outer wall 15. As a result, the contact laminations 5 in the contact section 13 are pressed against the outer wall 15. The laminar cage 3 is compressed.

[0105] Thus, in the second position P2, contact is made between the lamella cage 3 and the contact chamber 14 by the contacting sections 41 of the contact lamellae 3, thus providing a reliable electrical connection of the lamella cage to the connector 1 or the first component 50. At the same time, the coupling section 42 provides a reliable and good electrical connection to the contact element 9 and thus to the mating connector 2 and to the second component 60.

[0106] The laminar cage 3 can be made, for example, from a material with good electrical conductivity, such as copper or a copper alloy. The contact laminations 5 can be designed to be elastically reversible with regard to the displacement of the contact element 9 from the first position P1 to the second position P2. This means that when the contact element 9 is moved back from the second position P2 to the first position P1 or even further, the contact laminations 5 are moved (approximately) back to their initial position, which they had assumed in the force-free initial state. A new plug-in process can then take place, which in the second position P2 of the contact element 9 again leads to a displacement of the contact laminations 5 radially towards the outer wall 15 of the contact chamber 14 and to electrical contact being made therewith.

[0107] The insertion direction E can also be defined as the direction given by the displacement direction of the contact element 9 when contacting the laminar cage 3.

[0108] Figures 2a and 2b show perspective schematic views of two different lamella cages 3 of a connector 1.

[0109] Figure 2a shows a laminar cage 3 similar to that shown in Fig. 1, in which the contact laminations 5, starting from the base element 4, first transition into a rear section 6, from there into the contacting section 41, from there into the front section 7, and from there into the head element 40. In the rear section 6, the contact laminations 5 are connected to the base element 4. In the front section 7, the contact laminations 5 are connected to the head element 40. The head element 40 and base element 4 are, for example, closed in a ring shape. They can, for example, have a circular, elliptical, or polygonal cross-section (here: circular). The contacting sections 41 of the contact laminations 5 are clearly visible as being bulged radially outwards (towards the outer wall 15 of the contact chamber 14, not shown here).This bulging causes the contact laminations 5 to bulge further outwards in the event of axial compression of the laminar cage 3 and are not indifferent with regard to a possible radially inner and radially outer bulging.

[0110] Due to the closed design of the laminar cage 3 at both distal ends (base element 4 and head element 40), axial pressure on the coupling section 42, which is formed here, for example, by the head element 40, can be distributed particularly evenly across the contact laminations 5. Furthermore, this advantageously reduces the risk of the laminar cages 3 becoming entangled or damaging one another (e.g., as bulk material) during transport and handling of the laminar cages 3 as individual components during production.

[0111] Figure 2b shows a laminar cage 3 similar to that in Fig. 2a, but in which the contact laminations 5 have free ends 8 in their front section 7. Thus, the coupling section 42 is formed by the front section 7 of the contact laminations 5.

[0112] The free ends 8, for example, form the end face 33 here. The laminar cage 3 shown in Fig. 2b is particularly easy to manufacture. The slightly radially outwardly bent shape at the free end 8 advantageously prevents the free ends 8 from digging into the underside 35 when subjected to axial force by the contact element 9. A sliding surface is provided that particularly easily converts the axial force into a radial movement of the contact laminations 5 toward the outer wall 15 (here: radially outward).

[0113] Figure 2c shows a plan view of a stamped sheet as the initial state for a laminar cage 3 as shown in Figs 1 and 2a, i.e. with base element 4 and head element 40. This is therefore ultimately a two-dimensional preliminary stage of the laminar cage 3. In Fig. 2c, the base element 4 can be seen on the lower side and, projecting upwards from it, the majority of the contact laminations 5. The head element 40, to which the contact laminations 5 are connected, is arranged on the upper side. On the left side of the base element 4 and the head element 40 in Fig. 2c, two pins 25 can be seen, round here as an example, which are connected to the base element 4 by means of a neck region with a smaller diameter. On the right side of the base element 4 and the head element 40 in Fig. 2c, two recesses 24 complementary to the pins 25 (also with a neck area) can be seen.In order to design the laminar cage 3, this two-dimensional punched form can first be pressed or embossed, for example, to produce the desired shape of the contact laminations 5 (e.g., the contacting regions or contacting sections 41 that protrude radially outwards). The laminar cage 3 can then be formed by a winding process, wherein the pins 25 are latched or inserted into the recesses 24, and the laminar cage 3 is held dimensionally stable by means of the positive connection formed here between the base element 4 and the head element 40. In other embodiments, the base element 4 and / or the head element 40 can be connected by a material fit (e.g., soldered, welded, glued, etc.). In yet other embodiments, the base element 4 and / or the head element 40 can simply be wound and / or embossed, for example, so that it automatically maintains the predetermined shape, e.g.,is formed in a closed ring shape.

[0114] Figures 3a to 5b show schematic cross-sections through various connector assemblies 100. The mating connector 100 or the contact element 9 is shown in the first position P1 (Figs. 3a and 5a) or in the second position P2 (Figs. 3b, 4a, 4b, and 5b). One contact blade 5 can be seen to the left and right of the centering part 11, which is provided here only as an example. The centering part 11 has a centering part outer wall 19.

[0115] The laminar cage 3 in Figs. 3a, 3b, 4a, 5a, and 5b, for example, is designed similarly to that in Figs. 1 and 2a (with head element 40). The laminar cage 3 in Fig. 4b, for example, is designed similarly to that in Fig. 2b (without head element 40, with free ends 8), whereby its free ends 8 can even be bent outward. In principle, laminar cages similar to those in Fig. 2a or similar to those in Fig. 2b can be used in all embodiments.

[0116] In all embodiments shown, the laminar cage 3 can be arranged, for example, in the first position PI loosely or with radial play in the contact chamber 14.

[0117] Furthermore, it can be seen schematically in each case how the first component 50 is electrically connected to the connector 1 and how the second component 60 is electrically connected to the mating connector 2. For reasons of clarity, no actuating element for reducing the insertion force is shown in Figs. 3a to 5b, even though such an actuating element (e.g., a lever element, a slide element, or the like) may be optionally provided.

[0118] In the embodiment of Figs. 3a and 3b, the contact element 9 has a substantially planar or flat or smooth surface on its underside 35 facing the coupling section 42 of the laminar cage 3.

[0119] In other exemplary embodiments, a groove 16, in particular a circumferential one (see, for example, Figs. 4a, 4b, 5a and 5b), can be provided in or on the underside 35. In this case, such a groove 16 can, merely by way of example, have a funnel shape in cross-section with an initially obliquely running groove inner wall 18 and groove outer wall 22, wherein the groove inner wall 18 and groove outer wall 22 then run essentially parallel and / or perpendicular to the groove bottom 30, e.g. in the manner of a "Y" shape (see Fig. 4a). In this case, in particular the groove inner wall 18 can, for example, have a first angle W1 with respect to the insertion direction E, which is different from zero. For example, the first angle W1 of the groove inner wall 18 with respect to the insertion direction E can lie in a range between 2° and 45° or in a range between 3° and 15°.

[0120] Or the groove 16 can, for example, have a substantially vertical groove outer wall 22 and a substantially vertical groove inner wall 18, for example in the manner of a "U" shape or a rectangular shape (see Fig. 4b) or the groove 16 can have a groove outer wall 22 and a groove inner wall 18, which each run completely obliquely (i.e., for example, each have an angle not equal to 0° to the axial direction), for example in the manner of a "V" shape (see Figs. 5a and 5b).

[0121] In principle, it is also conceivable for such a groove 16 to have a semi-funnel shape, wherein in particular the groove inner wall 18 runs obliquely at least in sections (and, for example, has a first angle W1 as described above). Such an obliqueness not only enables radial centering of the contact element 9 and easier insertion. Alternatively or additionally, the obliqueness of the groove inner wall 18 can displace the coupling region 42 radially toward the outer wall 15 on the way from the first position P1 to the second position P2, in the manner of a slotted guide. This supports the application of the contact normal force to the outer wall 15 in addition to the compression of the contact blades 5 in the radial direction toward the outer wall 15.

[0122] Furthermore, it is also conceivable, for example, that the underside 35 is convexly curved, i.e., higher at the edge 17 than in the central region. In such a case, it can, for example, form a continuous surface without discontinuities (such as those caused by a groove 16).

[0123] Figure 3a shows the first position PI when plugging together the connector 1 and the mating connector 2. The contact element 9 here has a centering part 11, which already overlaps to a very large extent (almost 100%) with the laminar cage 3 (overlap along the insertion direction E). The underside 35 of the contact element 9 rests loosely on or against the end face 33, in this case on the head element 40, which here serves as a coupling section 42, for example. No or only a slight axial force (e.g., merely the force of gravity) is exerted by the contact element 9 on the coupling section 42 and thus on the contact laminations 5. It is also conceivable that in the first position PI the underside 35 is still somewhat spaced (e.g. between 1 μm and 500 μm, preferably between 1 μm and 200 μm) from the end face 33 of the coupling section 42, so that no force is exerted in the axial direction.

[0124] The contact chamber 14 also has, for example, a base 26. Arranged in the base 26 of the contact chamber 14 is a base recess 27, into which, for example, a front end 31 of the centering part 11 (here: a cantilevered end of the centering part 11) can be inserted (e.g., in the second position P2, see Fig. 3b). In this way, with the aid of the centering part 11, for example, the correct radial positioning of the contact element 9 in the second position P2 can be ensured, or the positioning tolerances during mating can be reduced.

[0125] Fig. 3a further shows that, at least up to the first position PI, the mating connector 2 or the contact element 9 can be displaced along the insertion direction E with a force of less than 5 N, in particular force-free, since up to the first position PI, no friction or unhooking forces, etc., occur between the contact element 9 and the laminar cage 3, even though a large part of the insertion path has already been covered. Furthermore, it can be seen that in the first position PI, a radial clearance is formed between the contact laminations 5 and the outer wall 15 of the contact chamber 14, here in the form of a gap 29.

[0126] Force-free displacement or displacement with a force of less than 5N refers in particular to forces necessary to overcome frictional forces, bulging forces, etc. Overcoming gravity, e.g., during overhead installation, should not be considered here.

[0127] In the first position PI, for example, the radial play between the contact blades 5 and the outer wall 15 is in a range between 5 µm and 200 µm or in a range between 20 µm and 100 µm, e.g., at 20 µm or 30 µm or 40 µm or 50 µm or 60 µm or 70 µm or 80 µm or 90 µm or 100 µm or 130 µm or 160 µm or 200 µm. In other words, the gap 29 creates the radial play and establishes a first distance D1 (in the radial direction R) in the range described above (e.g., between 5 µm and 200 µm, etc.).

[0128] Figure 3b shows the contact element 9 in the second position P2 (solid lines - the previous first position P1 from Fig. 3a is shown with dashed lines). The front end 31 of the centering part 11 is inserted into the bottom recess 27 of the bottom 26 of the contact chamber 14 or arranged in the bottom recess 27. For this purpose, the bottom recess 27 can, for example, have a particularly slight oversize (e.g. up to 500 μm, preferably up to 250 μm) compared to the front end 31. However, a press fit can also be formed, ie the front end 31 has a particularly slight oversize with respect to the diameter of the bottom recess 27. In this way, the contact element 9 is guided and / or secured in the radial direction 9, whereby a permanent and reliable contact is advantageously ensured even under adverse operating conditions (e.g. vibration loads, thermal cycling loads, etc.).

[0129] The first position PI and the second position P2 are, for example, spaced apart along the insertion direction E by a maximum of 5 mm, preferably by a maximum of 2 mm and most preferably by a maximum of 1 mm.

[0130] In other words, the second position P2 is spaced from the first position PI by a second distance D2 (viewed along the insertion direction E).

[0131] In the second position P2, the contact element 9 mechanically contacts the coupling section 42 of the laminar cage 3 in such a way that the contact laminations 5 are displaced along the radial direction R towards the outer wall 15 and the contacting sections 41 thereby electrically contact the contact section 13 of the outer wall and in particular clamp the laminar cage between them (in particular viewed along the radial direction R).

[0132] In other words: the contact element 9 presses or presses by means of its underside 35 onto the end face 33 of the coupling section 42, whereby the contact blades 5 deflect or tilt or are tilted or displaced or are displaced radially outward or toward the outer wall in the radial direction R. As a result, the outer wall 15 in the contact section 13 is subjected to a contact normal force by means of the contacting sections 41 of the contact blades 5, which, here by way of example, acts essentially in the radial direction R.

[0133] In this embodiment, it is provided, for example, that in the second position P2, the contact blades 5 contact the contact section 13 with a contact normal force in the radial direction R of at least 1N, preferably of at least 5N.

[0134] In addition to the contacting within the connector 1 (from the lamella cage 3 to the contact chamber 14), in the second position P2 an electrical contacting is also established between the connector 1 and the mating connector 2, which leads via the front side 33 of the coupling section 42 to the underside 35 of the head section 10 of the contact element.

[0135] This contact essentially runs along the axial direction.

[0136] Figs. 3a and 3b also show, purely schematically, an optional locking element 28, which secures the second position P2 against loosening. The locking element 28 is shown here merely symbolically or schematically as a type of slider, which can be guided through locking recesses 36 in the base 26 of the contact chamber 14 in the second position P2 and extends through a recess 32 in the centering part 11 in the area of ​​the base recess 27.

[0137] Figure 4a shows a schematic cross section through a further connector arrangement 100 in the second position P2, this connector arrangement 100 being designed similarly to that of Fig. 3b.

[0138] In contrast to Figs. 1, 3a, and 3b, however, no centering part 11 is provided on the contact element 9, even though a centering part could optionally be provided (just as in Figs. 1, 3a, 3b, the centering part 11 could optionally be omitted). The contact element 9 here has only the head section 10.

[0139] The plug connector arrangement 100 from Fig. 4a differs, however, from that from Fig. 3b, among other things, in that a groove 16 is introduced into the underside 35 of the contact element 9 on the side facing the laminar cage 3. This makes it possible, for example, to advantageously capture the end face 33 of the coupling section 42 and thus to arrange it in the correct radial position on or in the underside 35, e.g. already in the first position PI. If, in an embodiment not shown here, in which the laminar cage 3 does not have a head element 40, one or more contact laminations 5 are damaged or bent, for exampleIf the end face 33 is not in the correct radial position, or if the contact element 9 is placed slightly radially offset, then a (particularly radial) self-centering of the bent contact blade(s) 5 in the groove 16 and / or a radial self-centering of the contact element 9 can advantageously take place. If there is a significant bend in one or more contact blades 5, this can lead to a crooked position of the contact element 9, since some contact blades 5 are caught in the groove 16, while others are outside on the underside 35. Such a crooked position can be used by an assembler or a machine as an indication of a problem. The assembly quality can thus be advantageously improved.

[0140] In the second position P2, the coupling section 42, here the head element 40, is arranged in the groove 16.

[0141] Due to the funnel shape of the groove 16 shown here, the coupling section 42 in the second position P2 is electrically contacted on at least two sides, e.g. the groove inner wall 18 and the groove outer wall 22. In this embodiment, the coupling section 42 in the second position is even electrically and mechanically contacted on three sides: on the groove bottom 30 (in the axial direction) and on the groove inner wall 18 and the groove outer wall 22 (each in the radial direction R).

[0142] The optional locking element 28 for securing the second position P2 is designed here merely as an example as a type of clamp which clamps the contact element 9 and the contact chamber 14 together and thus secures the connector 1 and the mating connector 2 against displacement apart.

[0143] Figure 4b shows a schematic cross section through a further connector arrangement 100 in the second position P2, wherein this connector arrangement 100 is designed similarly to that of Fig. 4a, i.e. has a groove 16 in the head section 10.

[0144] In this embodiment, the contact element 9 also does not have a centering part 11, even though it could be provided optionally.

[0145] Here, however, the groove 16 has a substantially rectangular cross-section (e.g., similar to a U-shape). Furthermore, the laminar cage 3, for example, does not have a head element 40; rather, the contact laminations 5 are formed with free ends 8 in their front section 7.

[0146] It can also be seen that in this exemplary embodiment, the contact blades 5 in the front section 6 are bent outwards in the radial direction R (or in the direction of the outer wall 15, wherein the outer wall 15 is less high than the blade cage 3). Here, for example, they are bent relative to the insertion direction E by a second angle W2, which here, for example, is somewhat greater than 180° and, merely for example, can lie in a range between 185° and 260°. The second angle W2 can also be omitted entirely in other exemplary embodiments, or it can, for example, be at least 30°, preferably at least 60°, and particularly preferably at least 110°.

[0147] In this exemplary embodiment, in the second position P2, the contact blades 5 are arranged with their front sections 6 in the groove 16, wherein the front sections here form, for example, the coupling section 42. In this way, the contact blades 5 are advantageously secured against (radial) slipping out of the contacting position, e.g., even under strong vibration loads or thermal cycling. It cannot therefore easily happen that the end face 33 is briefly displaced radially outwards (e.g., due to an impact), causing the contact blade 5 to change its bending (e.g., into a bistable second state in which the contact blade 5 folds over radially inwards at the level of the contact section 13).

[0148] In this exemplary embodiment, the contact blades 5 each contact the groove 16 on at least two sides. The at least two sides are preferably spaced from each other by at least 30° (this is an angle in the illustrated image plane, not an angle along the circumferential direction U). One contact side is, for example, the groove inner wall 18. Another contact side is, for example, the groove bottom 30. In this exemplary embodiment, the contact blade 5 also contacts the groove outer wall 22. The front section 6 of the contact blades 5 is pressed together in the groove 16 due to the axial force applied by the contact element 9 in the second position P2 and fills the groove 16 significantly more in the second position P2 than in the first position P1.In this way, the contact area between contact blades 5 and contact element 9 is significantly enlarged, thereby significantly increasing the current-carrying capacity of the connector assembly 100 and reducing the contact resistance. Furthermore, the number of contact points is advantageously increased. This advantageously increases the redundancy of contact points, so that the connector assembly 100 is better protected against failures.

[0149] The optional locking element 28 for securing the second position P2 is designed here merely as an example, as in Fig. 4a, as a type of clamp. In this exemplary embodiment, the groove 16 runs diagonally outwards on the groove inner wall 18 towards the groove base 30. As a result, in addition to the radial tilting or displacement of the contact blades 5 caused by the axial force or compression (by the contact element 9), this displacement or tilting can be supplemented or supported by a form-fitting component. The inclined groove inner wall 18 acts like a link or link guide, which, upon axial movement of the contact element 9 along the insertion direction E, brings about a strictly defined radial displacement of the front section 7 of the contact blades 5 in the radial direction R towards the outer wall 15.

[0150] In this exemplary embodiment, it is provided that the first angle W1 of the groove outer wall 22 with respect to the insertion direction E lies in a range between 2° and 45° (i.e. a range of 2°-45°) or in a range between 3° and 15° (i.e. a range of 3°-15°).

[0151] As a result, when the contact element 9 is displaced from the first position PI to the second position P2 (i.e., by a distance corresponding to the second distance D2, see Figs. 3a and 3b), in addition to the axial force applied, it is ensured that the contact blades 5 move a defined distance in the radial direction R toward the outer wall 15, and that the desired contact normal force is thereby applied in the contact section 13 of the outer wall 15 by the contact blades 5 or their contacting sections 41. Furthermore, this has the effect of closing a gap 29 (see Fig. 3a), which is optionally present in the first position PI, between the contact blades 5 and the outer wall 15. Furthermore, this advantageously also enlarges a contact surface between the coupling section 42 and the contact element 9, thereby improving the electrical contact between the blade cage 3 and the contact element 9.

[0152] The optionally present locking element 28 is designed in the exemplary embodiment of Fig. 4b analogously to the locking element from Fig. 4a (as a type of clamp).

[0153] Figures 5a and 5b show schematic cross sections through a further connector arrangement 100 with the mating connector 2 in the first position P1 (Fig. 5a) and in the second position P2 (Fig. 5b), respectively. The contact element 9 is accommodated or arranged in a mating connector housing 61. Here, for example, it is mounted or arranged at its head section 10 in a contact element chamber 62 and is preferably secured with respect to the axial direction. Through this mounting, it can also be secured against tilting, for example. In this exemplary embodiment, the contact element

[0154] The cross-section shown shows two spaced-apart locking elements 52, which are arranged on the first component 50 and protrude from the first component 50 in the direction of the mating connector 2. The laminar cage 3 is arranged between them. The locking elements 52 have undercuts, for example.

[0155] In the cross-section shown, two counter-locking elements 63 can be seen on the mating connector housing 61. These elements protrude from the mating connector housing 61 in the direction of the connector 1 and each have a hook element. The counter-locking elements 63 can be designed as elastically reversible locking lances or clip elements (particularly along the radial direction R). The contact element 9 is arranged between the counter-locking elements 63.

[0156] In the first position PI shown in Fig. 5a, the counter-locking elements 63 can rest on the locking elements 52 and thus, for example, advantageously provide a technician with haptic feedback upon reaching the first position PI. In other embodiments, it can be provided, for example, that a captive connection between the connector 1 and the mating connector 2 is formed upon reaching (or even before reaching) the first position PI, so that the assembly can be transported in this state.

[0157] For example, the counter-locking elements 63 can slide past the undercuts of the locking elements 52 on the way from the first position P1 to the second position P2 (deflection radially outward in the exemplary embodiment shown) and, in the second position P2, can elastically and reversibly spring back radially inward to their initial position, so that their hook elements engage behind the undercuts of the locking elements 52. In this way, an unintentional release of the contact element 9 from the second position P2 toward the first position P1 is prevented. Locking elements 52 and counter-locking elements 63 thus form a type of locking element 28.

[0158] The laminar cage 3 is designed here, for example, analogously to the laminar cage shown in Fig. 2a. The underside 35 has, for example, a groove 16 in which the inner wall 18 and the outer wall 22 of the groove are both inclined and converge. It is shaped like a funnel. Here, the groove is designed, for example, in a "V" shape.

[0159] In the first position PI (Fig. 5a), the laminar cage 3 has, for example, a radial play with respect to the outer wall 15; here, for example, a gap 29 is formed (with the first distance D1) between the outer wall 15 and at least one contact lamina 5. In the second position P2 (Fig. 5b), the contact laminas 5 are in (mechanical) contact with the underside 35 or the groove 16 of the contact element 9 at or in their coupling section 42 (here: the head element 40). They are compressed by the axial force acting on the contact element (between the underside 35 and the base element 4 or between the head element 40 and the base element 4) and are thereby displaced in the radial direction R towards the outer wall 15, which they electrically contact in the contact section 13 and, in particular, apply a defined contact normal force. The lamella cage 3 can thus be clamped between the outer wall 15.

Claims

Connector arrangement, in particular for high-current applications and / or high-voltage applications, the connector arrangement (100) comprising: -- a connector (1); -- a mating connector (2) for plugging together with the plug connector (1); wherein the plug connector (1) has a lamella cage (3) with a base element (4) and with a plurality of contact lamellas (5), wherein the contact lamellas (5) -- are connected to the base element (4) in a rear section (6), -- protrude from the base element (4) in the direction of the mating connector (2) and -- have a front section (7) which faces the mating connector (2) and which has a cantilevered end (8) or by which the contact blades (5) are connected to a head element (40) of the blade cage (3), - have a contacting section (41) which is arranged between the rear section (6) and the front section (7), wherein the laminar cage (3) has a coupling section (42), wherein the plug connector (1) has a contact chamber (14) with an outer wall (15), wherein the laminar cage (3) is arranged in the contact chamber (14), wherein the contacting sections (41) are curved in the direction of the outer wall (15) with respect to the rear section (6) and the front section (7), wherein the mating connector (2) has a contact element (9) with an underside (35) facing the laminar cage (3), wherein the contact element (9) and / or the mating connector (2), in particular in the state plugged together with the plug connector (1), is displaceable between a first position (PI) and a second position (P2), in particular along a plug-in direction (E), wherein at least up to the first position (PI) the contact element (9) and / or the the mating connector (2) can be displaced along the insertion direction (E) with a force of less than 5N, in particular force-free, wherein in the second position (P2) the contact element (9) mechanically contacts the coupling section (42) of the lamella cage (3) in such a way that the contacting sections (41) of the contact lamellae (5) are displaced along a radial direction (R) to the outer wall (15) and the contacting sections (41) thereby electrically contact a contact section (13) of the outer wall (15) and in particular clamp the laminar cage (3) between the outer wall (15).

2. Connector arrangement according to the preceding claim, wherein in the second position (P2) the contact blades (5) contact the contact section (13) each with a contact normal force in the radial direction (R) of at least 1N, preferably of at least 5N.

3. Connector arrangement according to one of the preceding claims, wherein the base element (4) and / or the head element (40) of the laminar cage (3) is designed to be circumferentially closed, in particular annularly closed.

4. Connector arrangement according to one of the preceding claims, wherein the first position (PI) and the second position (P2) are located apart along the insertion direction (E) by at most 5 mm, preferably by at most 2 mm and particularly preferably by at most 1 mm.

5. Connector arrangement according to one of the preceding claims, wherein in the first position (PI) the radial play between the contacting section (41) and the outer wall (15) is in a range between 5 µm and 200 µm or in a range between 20 µm and 100 µm.

6. Connector arrangement according to one of the preceding claims, wherein a groove (16) with a groove inner wall (18), a groove bottom (30) and a groove outer wall (22) is introduced into the underside (35) of the contact element (9) for receiving the coupling section (42), in particular wherein in the second position (P2) the coupling section (42) in the groove (16), wherein the coupling section (42) contacts the groove (16), in particular on at least two sides. Connector arrangement according to the preceding claim, wherein in the second position (P2) the mechanical contacting of the coupling section (42) is effected by the groove base (30). Connector arrangement according to one of the two preceding claims, wherein a groove inner wall (18), in particular facing away from an outer edge (17) of the underside (35), runs obliquely outwards towards a groove base (30), wherein in particular a first angle (Wl) of the groove inner wall (18) with respect to the insertion direction (E) lies in a range between 2° and 45° or in a range between 3° and 15°. Connector arrangement according to one of the three preceding claims, wherein the groove (16) has a funnel shape in cross section.Plug connector arrangement according to one of the four preceding claims, wherein in the second position (P2) the coupling section (42) is clamped between the groove inner wall (18) and the groove outer wall (22), so that the coupling section (42) makes electrical contact with both the groove inner wall (18) and the groove outer wall (22). Plug connector, in particular for high-current applications and / or high-voltage applications, for plugging together with a mating plug connector (2) having a contact element, wherein the plug connector (1) has a lamella cage (3) with a base element (4) and with a plurality of contact lamellas (5), wherein the contact lamellas (5). - are connected to the base element (4) in a rear section (6), - protrude from the base element (4) in the direction of the mating connector (2) and - have a front section (7) which faces the mating connector (2) and which has a cantilevered end (8) or by which the contact blades (5) are connected to a head element (40) of the blade cage (3), -- have a contacting section (41) which is arranged between the rear section (6) and the front section (7), wherein the laminar cage (3) has a coupling section (42), wherein the plug connector (1) has a contact chamber (14) with an outer wall (15), wherein the laminar cage (3) is arranged in the contact chamber (14), wherein the contacting sections (41) are curved in the direction of the outer wall (15) with respect to the rear section (6) and the front section (7), wherein the laminar cage (3) is designed such that when a force is applied along an insertion direction (E) to the coupling section (42), in particular by the contact element,the contacting sections (41) of the contact lamellas (5) are displaced along a radial direction (R) towards the outer wall (15) and the contacting sections (41) thereby electrically contact a contact section (13) of the outer wall (15) and in particular clamp the lamella cage (3) between the outer wall (15).

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