Electrical connector secured by terminal position assurance and protected against penetration by solid foreign objects

Abstract

Electrical connector male terminal, secured and protected against the penetration of a foreign solid body, in wich: - an insulating male cap (5) is movable in a direction of connection between an unlocked position and a locked position, and comprises : an internal cavity into which a terminal conductor (3) extends both in the locked position and in the unlocked position; a contact cage (16) disposed on the walls of the internal cavity, the contact cage (16) being coupled with the insulating male cap (5) in the direction of connection (28); and - the male connector terminal has a terminal position assurance member which allows the insulating male cap (5) with contact cage (16) to pass to the locked position only if the terminal conductor (3) is in a predetermined correct position on the insulating socket (2).

Description

TECHNICAL FIELD

[0001] The invention relates to the field of electrical connectors with terminal position assurance means and with protection means against the penetration of a solid foreign body.

[0002] The field of secure electrical connectors concerns connectors equipped with means for securing connections, and in particular for prohibiting connections when a connector is not ready or when the connection does not offer the required level of security. In the field of secure connectors, TPA ("Terminal Position Assurance") devices are commonly used to prevent the connection of, for example, a male connector and a female connector under certain conditions.

[0003] The field of connectors protected against the penetration of a solid foreign body concerns connectors with protections that prevent a user from touching live parts. This technical field includes connectors that meet protection index standards such as IP2X.

[0004] In some industries, such as the automotive industry for the production of electric vehicles, connectors that meet both these requirements are needed.PRIOR ART

[0005] For example, known electric vehicles feature connector elements that are both secure and protected against the penetration of a solid foreign object. In particular, the electrical connectors used to connect traction batteries, which can be of high voltage and power, can represent a risk to the user and must be both secured and protected against the penetration of a solid foreign object.

[0006] Electrical connectors that are both secure and protected against the penetration of a solid foreign object are generally bulky and expensive.DISCLOSURE OF THE INVENTION

[0007] The aim of the invention is to improve the connectors of the prior art, which are secured and protected against the penetration of a solid foreign body.

[0008] To this end, the invention relates to an electrical connector male terminal, secured and protected against the penetration of a foreign solid body, comprising: an insulating base; a terminal conductor mounted in the insulating base and projecting from the insulating base; an insulating male cap which surrounds the terminal conductor, this insulating male cap comprising a connection slot allowing access to the terminal conductor and protecting against the penetration of a foreign solid body.

[0009] In this male connector terminal: the insulating male cap is movable in a direction of connection between an unlocked position, preventing connection of the male connector terminal, and a locked position allowing connection of the male connector terminal, the insulating male cap comprising : an internal cavity into which the terminal conductor extends both in the locked position and in the unlocked position; a contact cage disposed on the walls of the internal cavity, the contact cage being coupled with the insulating male cap in the direction of connection; and the male connector terminal has a terminal position assurance member which allows the insulating male cap with contact cage to pass to the locked position only if the terminal conductor is in a predetermined correct position on the insulating socket.

[0010] According to another object, the invention relates to an electrical connector comprising an electrical connector male terminal as defined above, and an electrical connector female terminal. In this connector, the female connector terminal comprises an insulating female cap surrounding the insulating male cap of the male connector terminal.

[0011] Electrical connectors according to the invention, secured and protected against the penetration of a solid foreign body, fulfill their safety and protection functions in a minimum space, increasing safety and reducing costs.

[0012] In addition to reducing materials and costs, the small footprint also directly contributes to the protective function, since it facilitates the use of small gaps around live parts.

[0013] The electrical connector male terminal according to the invention may comprise the following additional features, alone or in combination: the contact cage has a conductive support wall adjacent to the terminal conductor; the connection slot is located opposite a space of the internal cavity of the insulating male cap, this space being adapted to receive a female connection terminal, the terminal conductor being arranged between said space and the conductive support wall; the contact cage comprises a resilient contact element facing towards the conductive support wall; the resilient contact element comprises a resilient blade mounted on the contact cage; the resilient blade is mounted on a frame fixed to a wall of the contact cage by resilient flanges, the contact cage being mounted in the insulating male cap by clamping these resilient flanges; the contact cage has three adjacent walls and an open face; the contact cage has a fixing end cooperating with a rim of the insulating male cap; the insulating male cap comprises a lateral blade carrying a rim which is adapted to secure the contact cage in the insulating male cap; the terminal position assurance member comprises at least one locking lug arranged on the insulating base, and adapted to cooperate with the insulating male cap; the insulating male cap comprises a locking notch and an unlocking notch, and the locking lug is adapted to be housed respectively in the locking notch and in the unlocking notch for the locking and unlocking positions of the insulating male cap; the insulating male cap comprises a support collar provided with a through hole suitable for the passage of the locking lug; the terminal position assurance member comprises stopping tabs for the terminal conductor. PRESENTATION OF FIGURES

[0014] Further features and advantages of the invention will be apparent from the following non-limiting description, with reference to the appended drawings in which : Figure 1 is a perspective view of an electrical connector male terminal according to the invention; figure 2 is an exploded view of a female terminal adapted to the male terminal of figure 1 ; Figure 3 is an exploded view of the male terminal; Figure 4 is a cross-sectional view of the male terminal; Figure 5 shows the insulating base of the male terminal; Figure 6 shows a perspective view of the insulating male cap of the male terminal; Figure 7 is a top view of the insulating male cap; Figures 8 to 10 are cross-sectional views of the insulating male cap; Figure 11 is a cross-sectional view of the male terminal, with the male insulating cap in the unlocked position; Figure 12 is a cross-sectional view of the male terminal, with the male insulating cap in the locked position; figure 13 is a bottom view of the female connector shown in figure 2 ; figure 14 is a cross-sectional view of the connector according to the invention, with the male and female terminals connected together.

[0015] Elements which are similar and common to the various embodiments bear the same figure reference numbers.DETAILED DESCRIPTION

[0016] Figure 1 illustrates an electrical connector male terminal 1 according to the invention. This male terminal 1 is secured, i.e. its internal connector elements are guaranteed to be correctly positioned, and it is also protected against the penetration of a solid foreign body, i.e. its design prevents the user from gaining access to the live elements.

[0017] In the present example, the male terminal 1 is secured in the sense that electrical connection to this terminal is prevented if an internal terminal conductor are not correctly in place, and it also complies with protection class IP2X.

[0018] In the present example, the male terminal may be a connection terminal for an electric vehicle traction battery. The voltage of such batteries may be of the order of 100 to 800 volts.

[0019] The male terminal 1 comprises : an insulating base 2 which, in this example, can be integral with the battery case on which the terminal is mounted; a terminal conductor 3 which is mounted in the insulating base 2. In the present example, the terminal conductor 3 can be made of a busbar with a large cross-section and can be connected to a battery electrode by its end 4 ; an insulating male cap 5 which combines the functions of connection safety and protection against the penetration of a solid foreign body.

[0020] The insulating male cap 5 surrounds and protects the terminal conductor 3. The insulating male cap 5 has a connection slot 6, which enables connection to a complementary female terminal.

[0021] In the case of the present example (electric vehicle traction batteries), the male terminal 1 is a visible part, projecting from the battery pack, and enabling the electrical connection of one of the battery's electrodes. In principle, a battery pack will have at least two male terminals 1 such as the one described. This prevents the user from coming into contact with the live parts, even when the batteries are disconnected from their harness.

[0022] Figure 2 shows an example of a female terminal 7, in exploded view, which is adapted to the male terminal shown in Figure 1.

[0023] The female terminal 7 comprises an enclosure 8 made of insulating material and a female connection terminal 9 which is arranged in the enclosure 8 and connected to a suitable electrical harness or conductor (not shown).

[0024] The female terminal 7 also features an insulating female cap 10 which is inserted inside the enclosure 8 and surrounds the female connection terminal 9 to protect it too against the penetration of a solid foreign body.

[0025] Figure 3 is an exploded view of the male terminal 1. The male terminal 1 comprises a contact cage 16 which is arranged in the insulating male cap 5, these elements being mounted on a peripheral wall 11 of the insulating base 2.

[0026] The insulating male cap 5 is made of an insulating material. For example, it is molded in a polymer.

[0027] The contact cage 16 is an electrically conductive element designed to contact the terminal conductor 3 and the female connection terminal 9 when male terminal 1 and female terminal 7 are connected. The contact cage 16 is made by any suitable means, for example from folded sheet metal.

[0028] The terminal conductor 3 is thus inserted into a hole 17 in the insulating base 2 and is surrounded by the insulating male cap 5. The connection slot 6 provides access to the terminal conductor 3 only for the appropriate female connection terminal 9.

[0029] The male terminal 1 includes a terminal position assurance member, which ensures that the terminal conductor 3 is correctly positioned within the male terminal 1, preventing connection of the male terminal if the terminal conductor 3 is not in place or is not correctly positioned.

[0030] Figure 4 is a cross-sectional view of the male terminal 1 in its nominal state, i.e. mounted and ready for connection. The connection is made along a direction of connection 28 shown in the figure.

[0031] In this position, the insulating male cap 5 is in a locked position.

[0032] The terminal conductor 3 is positioned in a sleeve 18 of the insulating base 2, so that it protrudes from the insulating base 2.

[0033] The male insulating cap 5 has a support collar 19 which rests on the peripheral wall 11 of the insulating base 2 when the male insulating cap 5 is in this locking position.

[0034] The insulating male cap 5 has an internal cavity into which the terminal conductor extends. The contact cage 16 is arranged in this inner cavity of the insulating male cap 5, and has a conductive support wall 20 adjacent to the terminal conductor 3, against which the latter can be positioned.

[0035] The connection slot 6 is located opposite a space 37 in the inner cavity, and this space 37 is provided for the female connection terminal 9 (see figure 14). The terminal conductor 9 is arranged between said space 37 and the conductive support wall 20.

[0036] The contact cage 16 has a resilient contact element 21 (visible in Figures 8 and 9) which faces in the direction of the conductive support wall 20, and is intended to press the female connection terminal 9 and the male terminal conductor 3 against the conductive support wall 20.

[0037] Female connection terminal 9 and male terminal conductor 3 are thus electrically connected and surrounded by contact cage 16 and insulating male cap 5.

[0038] Figure 5 illustrates the insulating base 2 of the male terminal 1.

[0039] The insulating base 2 comprises: a peripheral wall 11 for positioning and supporting the insulating male cap 5 on the insulating base 2; two elastically deformable stopping tabs 12 which is part of the terminal position assurance member. For this purpose, the resilient stopping tabs 12 each have a tooth 13 at their end. This tooth 13 prevents the insulating male cap 5 from moving into the locking position if the terminal conductor 3 is not correctly mounted in the insulating base 2.

[0040] The insulating base 2 also features elastically deformable locking lugs 14, each with a catch 15 at the end. The stopping tabs 12 and the locking lugs 14 are located inside the perimeter delimited by the peripheral wall 11, and are intended to interact with the terminal conductor 3 and the insulating male cap 5 as described below.

[0041] Figures 6 to 10 illustrate the assembly of the contact cage 16 in the insulating male cap 5: figure 6 is a perspective view of the assembly; figure 7 is a top view; figure 8 is a cross-sectional view following section A-A of figure 7; figure 9 is a perspective view of the section of figure 8; figure 10 is a view following section B-B of figure 7.

[0042] Referring to Figure 6, the insulating male cap 5 has through-holes 22 in the support collar 19, through which the locking lugs 14 can pass.

[0043] The cross-sections in Figures 8, 9 and 10 show how the contact cage 7 is mounted in the insulating male cap 5. The contact cage 16 has a fastening end 23 on the lower part of its conductive support wall 20, which enables it to be clipped into the insulating male cap 5 by bending. In the present example, this fastening end 23 is formed by a curved portion of the rim of the conductive support wall 20, which rests on a rim 24 of the inner wall of the insulating male cap 5.

[0044] The contact cage 16, which is preferably made from bent sheet metal, has elastic properties which are exploited for positioning in the insulating male cap 5.

[0045] The contact cage 16 is thus held in place between the rim 24 and an opposite face of the insulating male cap 5.

[0046] On the wall 36 of the contact cage 16 facing the conductive support wall 20, the contact cage 16 carries the elastic contact element 21. Advantageously, in the present example, the elastic contact element 21 contributes to the positioning of the contact cage 16 and its elastic properties are used to this end.

[0047] The resilient contact element 21 comprises in this example a resilient blade 27 mounted on an frame 35 which is secured to the wall 36 by resilient flanges 34. The contact cage 16 is mounted in the insulating male cap 5 by clamping these resilient flanges 34 between an rim 25 of the insulating male cap 5 and an opposite face of the insulating male cap 5.

[0048] Figure 10 is a cross-sectional view of the insulating male cap 5 without the contact cage 16, showing a lateral blade 38 bearing a rim 26 also suitable for securing the contact cage 16 in the insulating male cap 5.

[0049] Advantageously, contact cage 16 consists of three adjacent walls (conductive support wall 20, wall 36 and central wall 39) and has an open face. This structure enables easy and safe assembly, with few moving parts: the contact cage 16 is assembled by inserting it into the insulating male cap 5, so that the two opposing walls 20 and 36 are brought together by elastic deformation of the contact cage 16 to pass the rims 24 and 25. During this same insertion operation, the lateral blade 38 is pushed back. At the end of the operation, lateral blade 38 returns to position and locks contact cage 16 with rim 26, while the other walls are locked by rims 24 and 25.

[0050] The contact cage 16 is thus coupled with the insulating male cap 5 in the direction of connection 28.

[0051] In the present example, contact cage 16 is coupled with insulating male cap 5 in direction of connection 28, being completely fixed in insulating male cap 5. Only coupling of contact cage 16 and insulating male cap 5 along direction of connection 28 is necessary, and, alternatively, contact cage 16 can be movable in insulating male cap 5 in both directions perpendicular to direction of connection 28.

[0052] The contact cage 16 is thus movable together with the insulating male cap 5 as the latter moves in the direction of connection 28. The insulating male cap 5 is in fact movable on the insulating base 2 along the direction of connection 28 between a locked position and an unlocked position, and the contact cage 16 thus accompanies the insulating male cap 5 in its movement.

[0053] Figure 11 is a cross-sectional view showing the male terminal 1 being assembled. The insulating male cap 5, together with the contact cage 16, is in a locking position.

[0054] In this position, the catches 15 of the locking lugs 14 are each inserted into an unlocking notch 29 provided in the insulating male cap 5. The unlocking notches 29 are designed to hold the insulating male cap 5 at the height shown in this figure 11.

[0055] In a first assembly step, the male insulating cap 5 is placed on the insulating base 2 in an unlocked position. The terminal conductor 3 is then positioned in the insulating base 2 (position shown in Figure 11). When the male insulating cap 5 is in its unlocked position, the terminal conductor 3 can be inserted into the sleeve 18 of the insulating base 2 until the stopping tabs 12 engage in lateral notches 31 of the terminal conductor 3. The terminal conductor 3 is then in its predetermined correct position.

[0056] As long as the terminal conductor 3 is not in its correct position, the insulating male cap 5 cannot be moved to its locking position.

[0057] The insulating male cap is then pushed back into its locking position, with the caches 15 of the locking lugs 14 engaging in locking notches 30 on the insulating male cap 5.

[0058] Figure 12 shows the male terminal 1 in a cross-section perpendicular to the cross-section in Figure 11, passing through the plane in which the terminal conductor 3 extends. Figure 12 shows the terminal conductor 3 in its correct position, and the insulating male cap 5 in its locking position.

[0059] As long as the terminal conductor 3 has not been fully inserted into its correct position, where the stopping tabs 12 snap into the side notches 31, the stopping tabs 12 remain spread apart, abutting the body of the terminal conductor 3. In this position, if an attempt is made to lower the male insulating cap 5, bringing it closer to the insulating base 2 in the direction of connection 28, the teeth 13 of the stopping tabs 12 come up against the lower peripheral edge of the male insulating cap 5, preventing the latter from getting its locked position. The terminal position assurance function is thus fulfilled.

[0060] When the insulating male cap 5 is in its locking position, the locking lugs 14 are in position in the locking notches 30, and the support collar 19 of the insulating male cap 5 comes against the peripheral wall 11, making it possible to connect the corresponding female terminal.

[0061] Figures 13 and 14 show how to connect the female terminal to the male terminal described above.

[0062] Figure 13 is a view from below, illustrating the connection side of the female terminal 7 shown in Figure 2. Female terminal 7 has its insulating female cap 10, recessed in its casing 8, surrounding and protecting female connection terminal 9.

[0063] The insulating female cap 10 also features an insulating lip 32 covering the edge of the female connection terminal 9, so that the user cannot come into contact with the edge.

[0064] In addition, the distance D2 between the female connection terminal 9 and each edge of the casing 8, is dimensioned to guarantee protection against the permeation of a foreign solid body. For example, in the case of IP2X protection, the distance D2 is less than 12.5 cm.

[0065] A small value for the distance D2 is made possible by the small dimensions of the male terminal 1, between the connection slot 6 and the edges of the insulating male cap 5.

[0066] Figure 14 is a sectional view showing the male terminal 1 described and the female terminal 7 connected.

[0067] The female connection terminal 9 is positioned in space 37 against the terminal conductor 3, and these two elements are pressed against each other and against the conductive support wall 20 of the contact cage 16, by the elastic contact element 21.

[0068] The assembly of the insulating male cap 5 and the contact cage 16 coupled to it, allow a reduced dimensioning of the distance D1 on the male terminal 1 (width of the connection slot 6), and of the distance D2 on the female terminal 7, thus enabling the male and female terminals of the connector to be protected against the penetration of a foreign solid body.

Examples

Embodiment Construction

[0016]Figure 1 illustrates an electrical connector male terminal 1 according to the invention. This male terminal 1 is secured, i.e. its internal connector elements are guaranteed to be correctly positioned, and it is also protected against the penetration of a solid foreign body, i.e. its design prevents the user from gaining access to the live elements.

[0017]In the present example, the male terminal 1 is secured in the sense that electrical connection to this terminal is prevented if an internal terminal conductor are not correctly in place, and it also complies with protection class IP2X.

[0018]In the present example, the male terminal may be a connection terminal for an electric vehicle traction battery. The voltage of such batteries may be of the order of 100 to 800 volts.

[0019]The male terminal 1 comprises :

an insulating base 2 which, in this example, can be integral with the battery case on which the terminal is mounted; a terminal conductor 3 which is mounted in the insulat...

TECHNICAL FIELD

[0001] The invention relates to the field of electrical connectors with terminal position assurance means and with protection means against the penetration of a solid foreign body.

[0002] The field of secure electrical connectors concerns connectors equipped with means for securing connections, and in particular for prohibiting connections when a connector is not ready or when the connection does not offer the required level of security. In the field of secure connectors, TPA ("Terminal Position Assurance") devices are commonly used to prevent the connection of, for example, a male connector and a female connector under certain conditions.

[0003] The field of connectors protected against the penetration of a solid foreign body concerns connectors with protections that prevent a user from touching live parts. This technical field includes connectors that meet protection index standards such as IP2X.

[0004] In some industries, such as the automotive industry for the production of electric vehicles, connectors that meet both these requirements are needed.PRIOR ART

[0005] For example, known electric vehicles feature connector elements that are both secure and protected against the penetration of a solid foreign object. In particular, the electrical connectors used to connect traction batteries, which can be of high voltage and power, can represent a risk to the user and must be both secured and protected against the penetration of a solid foreign object.

[0006] Electrical connectors that are both secure and protected against the penetration of a solid foreign object are generally bulky and expensive.DISCLOSURE OF THE INVENTION

[0007] The aim of the invention is to improve the connectors of the prior art, which are secured and protected against the penetration of a solid foreign body.

[0008] To this end, the invention relates to an electrical connector male terminal, secured and protected against the penetration of a foreign solid body, comprising: an insulating base; a terminal conductor mounted in the insulating base and projecting from the insulating base; an insulating male cap which surrounds the terminal conductor, this insulating male cap comprising a connection slot allowing access to the terminal conductor and protecting against the penetration of a foreign solid body.

[0009] In this male connector terminal: the insulating male cap is movable in a direction of connection between an unlocked position, preventing connection of the male connector terminal, and a locked position allowing connection of the male connector terminal, the insulating male cap comprising : an internal cavity into which the terminal conductor extends both in the locked position and in the unlocked position; a contact cage disposed on the walls of the internal cavity, the contact cage being coupled with the insulating male cap in the direction of connection; and the male connector terminal has a terminal position assurance member which allows the insulating male cap with contact cage to pass to the locked position only if the terminal conductor is in a predetermined correct position on the insulating socket.

[0010] According to another object, the invention relates to an electrical connector comprising an electrical connector male terminal as defined above, and an electrical connector female terminal. In this connector, the female connector terminal comprises an insulating female cap surrounding the insulating male cap of the male connector terminal.

[0011] Electrical connectors according to the invention, secured and protected against the penetration of a solid foreign body, fulfill their safety and protection functions in a minimum space, increasing safety and reducing costs.

[0012] In addition to reducing materials and costs, the small footprint also directly contributes to the protective function, since it facilitates the use of small gaps around live parts.

[0013] The electrical connector male terminal according to the invention may comprise the following additional features, alone or in combination: the contact cage has a conductive support wall adjacent to the terminal conductor; the connection slot is located opposite a space of the internal cavity of the insulating male cap, this space being adapted to receive a female connection terminal, the terminal conductor being arranged between said space and the conductive support wall; the contact cage comprises a resilient contact element facing towards the conductive support wall; the resilient contact element comprises a resilient blade mounted on the contact cage; the resilient blade is mounted on a frame fixed to a wall of the contact cage by resilient flanges, the contact cage being mounted in the insulating male cap by clamping these resilient flanges; the contact cage has three adjacent walls and an open face; the contact cage has a fixing end cooperating with a rim of the insulating male cap; the insulating male cap comprises a lateral blade carrying a rim which is adapted to secure the contact cage in the insulating male cap; the terminal position assurance member comprises at least one locking lug arranged on the insulating base, and adapted to cooperate with the insulating male cap; the insulating male cap comprises a locking notch and an unlocking notch, and the locking lug is adapted to be housed respectively in the locking notch and in the unlocking notch for the locking and unlocking positions of the insulating male cap; the insulating male cap comprises a support collar provided with a through hole suitable for the passage of the locking lug; the terminal position assurance member comprises stopping tabs for the terminal conductor. PRESENTATION OF FIGURES

[0014] Further features and advantages of the invention will be apparent from the following non-limiting description, with reference to the appended drawings in which : Figure 1 is a perspective view of an electrical connector male terminal according to the invention; figure 2 is an exploded view of a female terminal adapted to the male terminal of figure 1 ; Figure 3 is an exploded view of the male terminal; Figure 4 is a cross-sectional view of the male terminal; Figure 5 shows the insulating base of the male terminal; Figure 6 shows a perspective view of the insulating male cap of the male terminal; Figure 7 is a top view of the insulating male cap; Figures 8 to 10 are cross-sectional views of the insulating male cap; Figure 11 is a cross-sectional view of the male terminal, with the male insulating cap in the unlocked position; Figure 12 is a cross-sectional view of the male terminal, with the male insulating cap in the locked position; figure 13 is a bottom view of the female connector shown in figure 2 ; figure 14 is a cross-sectional view of the connector according to the invention, with the male and female terminals connected together.

[0015] Elements which are similar and common to the various embodiments bear the same figure reference numbers.DETAILED DESCRIPTION

[0016] Figure 1 illustrates an electrical connector male terminal 1 according to the invention. This male terminal 1 is secured, i.e. its internal connector elements are guaranteed to be correctly positioned, and it is also protected against the penetration of a solid foreign body, i.e. its design prevents the user from gaining access to the live elements.

[0017] In the present example, the male terminal 1 is secured in the sense that electrical connection to this terminal is prevented if an internal terminal conductor are not correctly in place, and it also complies with protection class IP2X.

[0018] In the present example, the male terminal may be a connection terminal for an electric vehicle traction battery. The voltage of such batteries may be of the order of 100 to 800 volts.

[0019] The male terminal 1 comprises : an insulating base 2 which, in this example, can be integral with the battery case on which the terminal is mounted; a terminal conductor 3 which is mounted in the insulating base 2. In the present example, the terminal conductor 3 can be made of a busbar with a large cross-section and can be connected to a battery electrode by its end 4 ; an insulating male cap 5 which combines the functions of connection safety and protection against the penetration of a solid foreign body.

[0020] The insulating male cap 5 surrounds and protects the terminal conductor 3. The insulating male cap 5 has a connection slot 6, which enables connection to a complementary female terminal.

[0021] In the case of the present example (electric vehicle traction batteries), the male terminal 1 is a visible part, projecting from the battery pack, and enabling the electrical connection of one of the battery's electrodes. In principle, a battery pack will have at least two male terminals 1 such as the one described. This prevents the user from coming into contact with the live parts, even when the batteries are disconnected from their harness.

[0022] Figure 2 shows an example of a female terminal 7, in exploded view, which is adapted to the male terminal shown in Figure 1.

[0023] The female terminal 7 comprises an enclosure 8 made of insulating material and a female connection terminal 9 which is arranged in the enclosure 8 and connected to a suitable electrical harness or conductor (not shown).

[0024] The female terminal 7 also features an insulating female cap 10 which is inserted inside the enclosure 8 and surrounds the female connection terminal 9 to protect it too against the penetration of a solid foreign body.

[0025] Figure 3 is an exploded view of the male terminal 1. The male terminal 1 comprises a contact cage 16 which is arranged in the insulating male cap 5, these elements being mounted on a peripheral wall 11 of the insulating base 2.

[0026] The insulating male cap 5 is made of an insulating material. For example, it is molded in a polymer.

[0027] The contact cage 16 is an electrically conductive element designed to contact the terminal conductor 3 and the female connection terminal 9 when male terminal 1 and female terminal 7 are connected. The contact cage 16 is made by any suitable means, for example from folded sheet metal.

[0028] The terminal conductor 3 is thus inserted into a hole 17 in the insulating base 2 and is surrounded by the insulating male cap 5. The connection slot 6 provides access to the terminal conductor 3 only for the appropriate female connection terminal 9.

[0029] The male terminal 1 includes a terminal position assurance member, which ensures that the terminal conductor 3 is correctly positioned within the male terminal 1, preventing connection of the male terminal if the terminal conductor 3 is not in place or is not correctly positioned.

[0030] Figure 4 is a cross-sectional view of the male terminal 1 in its nominal state, i.e. mounted and ready for connection. The connection is made along a direction of connection 28 shown in the figure.

[0031] In this position, the insulating male cap 5 is in a locked position.

[0032] The terminal conductor 3 is positioned in a sleeve 18 of the insulating base 2, so that it protrudes from the insulating base 2.

[0033] The male insulating cap 5 has a support collar 19 which rests on the peripheral wall 11 of the insulating base 2 when the male insulating cap 5 is in this locking position.

[0034] The insulating male cap 5 has an internal cavity into which the terminal conductor extends. The contact cage 16 is arranged in this inner cavity of the insulating male cap 5, and has a conductive support wall 20 adjacent to the terminal conductor 3, against which the latter can be positioned.

[0035] The connection slot 6 is located opposite a space 37 in the inner cavity, and this space 37 is provided for the female connection terminal 9 (see figure 14). The terminal conductor 9 is arranged between said space 37 and the conductive support wall 20.

[0036] The contact cage 16 has a resilient contact element 21 (visible in Figures 8 and 9) which faces in the direction of the conductive support wall 20, and is intended to press the female connection terminal 9 and the male terminal conductor 3 against the conductive support wall 20.

[0037] Female connection terminal 9 and male terminal conductor 3 are thus electrically connected and surrounded by contact cage 16 and insulating male cap 5.

[0038] Figure 5 illustrates the insulating base 2 of the male terminal 1.

[0039] The insulating base 2 comprises: a peripheral wall 11 for positioning and supporting the insulating male cap 5 on the insulating base 2; two elastically deformable stopping tabs 12 which is part of the terminal position assurance member. For this purpose, the resilient stopping tabs 12 each have a tooth 13 at their end. This tooth 13 prevents the insulating male cap 5 from moving into the locking position if the terminal conductor 3 is not correctly mounted in the insulating base 2.

[0040] The insulating base 2 also features elastically deformable locking lugs 14, each with a catch 15 at the end. The stopping tabs 12 and the locking lugs 14 are located inside the perimeter delimited by the peripheral wall 11, and are intended to interact with the terminal conductor 3 and the insulating male cap 5 as described below.

[0041] Figures 6 to 10 illustrate the assembly of the contact cage 16 in the insulating male cap 5: figure 6 is a perspective view of the assembly; figure 7 is a top view; figure 8 is a cross-sectional view following section A-A of figure 7; figure 9 is a perspective view of the section of figure 8; figure 10 is a view following section B-B of figure 7.

[0042] Referring to Figure 6, the insulating male cap 5 has through-holes 22 in the support collar 19, through which the locking lugs 14 can pass.

[0043] The cross-sections in Figures 8, 9 and 10 show how the contact cage 7 is mounted in the insulating male cap 5. The contact cage 16 has a fastening end 23 on the lower part of its conductive support wall 20, which enables it to be clipped into the insulating male cap 5 by bending. In the present example, this fastening end 23 is formed by a curved portion of the rim of the conductive support wall 20, which rests on a rim 24 of the inner wall of the insulating male cap 5.

[0044] The contact cage 16, which is preferably made from bent sheet metal, has elastic properties which are exploited for positioning in the insulating male cap 5.

[0045] The contact cage 16 is thus held in place between the rim 24 and an opposite face of the insulating male cap 5.

[0046] On the wall 36 of the contact cage 16 facing the conductive support wall 20, the contact cage 16 carries the elastic contact element 21. Advantageously, in the present example, the elastic contact element 21 contributes to the positioning of the contact cage 16 and its elastic properties are used to this end.

[0047] The resilient contact element 21 comprises in this example a resilient blade 27 mounted on an frame 35 which is secured to the wall 36 by resilient flanges 34. The contact cage 16 is mounted in the insulating male cap 5 by clamping these resilient flanges 34 between an rim 25 of the insulating male cap 5 and an opposite face of the insulating male cap 5.

[0048] Figure 10 is a cross-sectional view of the insulating male cap 5 without the contact cage 16, showing a lateral blade 38 bearing a rim 26 also suitable for securing the contact cage 16 in the insulating male cap 5.

[0049] Advantageously, contact cage 16 consists of three adjacent walls (conductive support wall 20, wall 36 and central wall 39) and has an open face. This structure enables easy and safe assembly, with few moving parts: the contact cage 16 is assembled by inserting it into the insulating male cap 5, so that the two opposing walls 20 and 36 are brought together by elastic deformation of the contact cage 16 to pass the rims 24 and 25. During this same insertion operation, the lateral blade 38 is pushed back. At the end of the operation, lateral blade 38 returns to position and locks contact cage 16 with rim 26, while the other walls are locked by rims 24 and 25.

[0050] The contact cage 16 is thus coupled with the insulating male cap 5 in the direction of connection 28.

[0051] In the present example, contact cage 16 is coupled with insulating male cap 5 in direction of connection 28, being completely fixed in insulating male cap 5. Only coupling of contact cage 16 and insulating male cap 5 along direction of connection 28 is necessary, and, alternatively, contact cage 16 can be movable in insulating male cap 5 in both directions perpendicular to direction of connection 28.

[0052] The contact cage 16 is thus movable together with the insulating male cap 5 as the latter moves in the direction of connection 28. The insulating male cap 5 is in fact movable on the insulating base 2 along the direction of connection 28 between a locked position and an unlocked position, and the contact cage 16 thus accompanies the insulating male cap 5 in its movement.

[0053] Figure 11 is a cross-sectional view showing the male terminal 1 being assembled. The insulating male cap 5, together with the contact cage 16, is in a locking position.

[0054] In this position, the catches 15 of the locking lugs 14 are each inserted into an unlocking notch 29 provided in the insulating male cap 5. The unlocking notches 29 are designed to hold the insulating male cap 5 at the height shown in this figure 11.

[0055] In a first assembly step, the male insulating cap 5 is placed on the insulating base 2 in an unlocked position. The terminal conductor 3 is then positioned in the insulating base 2 (position shown in Figure 11). When the male insulating cap 5 is in its unlocked position, the terminal conductor 3 can be inserted into the sleeve 18 of the insulating base 2 until the stopping tabs 12 engage in lateral notches 31 of the terminal conductor 3. The terminal conductor 3 is then in its predetermined correct position.

[0056] As long as the terminal conductor 3 is not in its correct position, the insulating male cap 5 cannot be moved to its locking position.

[0057] The insulating male cap is then pushed back into its locking position, with the caches 15 of the locking lugs 14 engaging in locking notches 30 on the insulating male cap 5.

[0058] Figure 12 shows the male terminal 1 in a cross-section perpendicular to the cross-section in Figure 11, passing through the plane in which the terminal conductor 3 extends. Figure 12 shows the terminal conductor 3 in its correct position, and the insulating male cap 5 in its locking position.

[0059] As long as the terminal conductor 3 has not been fully inserted into its correct position, where the stopping tabs 12 snap into the side notches 31, the stopping tabs 12 remain spread apart, abutting the body of the terminal conductor 3. In this position, if an attempt is made to lower the male insulating cap 5, bringing it closer to the insulating base 2 in the direction of connection 28, the teeth 13 of the stopping tabs 12 come up against the lower peripheral edge of the male insulating cap 5, preventing the latter from getting its locked position. The terminal position assurance function is thus fulfilled.

[0060] When the insulating male cap 5 is in its locking position, the locking lugs 14 are in position in the locking notches 30, and the support collar 19 of the insulating male cap 5 comes against the peripheral wall 11, making it possible to connect the corresponding female terminal.

[0061] Figures 13 and 14 show how to connect the female terminal to the male terminal described above.

[0062] Figure 13 is a view from below, illustrating the connection side of the female terminal 7 shown in Figure 2. Female terminal 7 has its insulating female cap 10, recessed in its casing 8, surrounding and protecting female connection terminal 9.

[0063] The insulating female cap 10 also features an insulating lip 32 covering the edge of the female connection terminal 9, so that the user cannot come into contact with the edge.

[0064] In addition, the distance D2 between the female connection terminal 9 and each edge of the casing 8, is dimensioned to guarantee protection against the permeation of a foreign solid body. For example, in the case of IP2X protection, the distance D2 is less than 12.5 cm.

[0065] A small value for the distance D2 is made possible by the small dimensions of the male terminal 1, between the connection slot 6 and the edges of the insulating male cap 5.

[0066] Figure 14 is a sectional view showing the male terminal 1 described and the female terminal 7 connected.

[0067] The female connection terminal 9 is positioned in space 37 against the terminal conductor 3, and these two elements are pressed against each other and against the conductive support wall 20 of the contact cage 16, by the elastic contact element 21.

[0068] The assembly of the insulating male cap 5 and the contact cage 16 coupled to it, allow a reduced dimensioning of the distance D1 on the male terminal 1 (width of the connection slot 6), and of the distance D2 on the female terminal 7, thus enabling the male and female terminals of the connector to be protected against the penetration of a foreign solid body.

Examples

Embodiment Construction

[0016]Figure 1 illustrates an electrical connector male terminal 1 according to the invention. This male terminal 1 is secured, i.e. its internal connector elements are guaranteed to be correctly positioned, and it is also protected against the penetration of a solid foreign body, i.e. its design prevents the user from gaining access to the live elements.

[0017]In the present example, the male terminal 1 is secured in the sense that electrical connection to this terminal is prevented if an internal terminal conductor are not correctly in place, and it also complies with protection class IP2X.

[0018]In the present example, the male terminal may be a connection terminal for an electric vehicle traction battery. The voltage of such batteries may be of the order of 100 to 800 volts.

[0019]The male terminal 1 comprises :

an insulating base 2 which, in this example, can be integral with the battery case on which the terminal is mounted; a terminal conductor 3 which is mounted in the insulat...

Claims

1. Electrical connector male terminal, secured and protected against the penetration of a foreign solid body, comprising: an insulating base (2); a terminal conductor (3) mounted in the insulating base (2) and projecting from the insulating base (2); an insulating male cap (5) which surrounds the terminal conductor (3), this insulating male cap (5) comprising a connection slot (6) allowing access to the terminal conductor (3) and protecting against the penetration of a foreign solid body; this male connector terminal being characterized in that : - the insulating male cap (5) is movable in a direction of connection (28) between an unlocked position, preventing connection of the male connector terminal, and a locked position allowing connection of the male connector terminal, the insulating male cap (5) comprising : an internal cavity into which the terminal conductor (3) extends both in the locked position and in the unlocked position; a contact cage (16) disposed on the walls of the internal cavity, the contact cage (16) being coupled with the insulating male cap (5) in the direction of connection (28); and in that - the male connector terminal has a terminal position assurance member which allows the insulating male cap (5) with contact cage (16) to pass to the locked position only if the terminal conductor (3) is in a predetermined correct position on the insulating socket (2).

2. Electrical connector male terminal according to claim 1, characterized in that the contact cage (16) has a conductive support wall (20) adjacent to the terminal conductor (3).

3. Electrical connector male terminal according to claim 2, characterized in that the connection slot (6) is located opposite a space (37) of the internal cavity of the insulating male cap (5), this space (37) being adapted to receive a female connection terminal (9), the terminal conductor (3) being arranged between said space (37) and the conductive support wall (20).

4. Electrical connector male terminal according to one of claims 2 or 3, characterized in that the contact cage (16) comprises a resilient contact element (21) facing towards the conductive support wall (20).

5. Electrical connector male terminal according to claim 4, characterized in that the resilient contact element (21) comprises a resilient blade (27) mounted on the contact cage (16).

6. Electrical connector male terminal according to claim 5, characterized in that the resilient blade (27) is mounted on a frame (35) fixed to a wall (36) of the contact cage (16) by resilient flanges (34), the contact cage (16) being mounted in the insulating male cap (5) by clamping these resilient flanges (34).

7. Electrical connector male terminal according to one of the preceding claims, characterized in that the contact cage (16) has three adjacent walls (20, 36, 39) and an open face.

8. Electrical connector male terminal according to one of the preceding claims, characterized in that the contact cage (16) has a fixing end (23) cooperating with a rim (24) of the insulating male cap (5).

9. Electrical connector male terminal according to one of the preceding claims, characterized in that the insulating male cap (5) comprises a lateral blade (38) carrying a rim (26) which is adapted to secure the contact cage (16) in the insulating male cap (5).

10. Electrical connector male terminal according to one of the preceding claims, characterized in that the terminal position assurance member comprises at least one locking lug (14) arranged on the insulating base (2), and adapted to cooperate with the insulating male cap (5).

11. Electrical connector male terminal according to claim 10, characterized in that the insulating male cap (5) comprises a locking notch (30) and an unlocking notch (29), and in that the locking lug (14) is adapted to be housed respectively in the locking notch (30) and in the unlocking notch (29) for the locking and unlocking positions of the insulating male cap (5).

12. Electrical connector male terminal according to one of claims 10 or 11, characterized in that the insulating male cap (5) comprises a support collar (19) provided with a through hole (22) suitable for the passage of the locking lug (14).

13. Electrical connector male terminal according to one of the preceding claims, characterized in that the terminal position assurance member comprises stopping tabs (12) for the terminal conductor (3).

14. Electrical connector comprising an electrical connector male terminal according to one of claims 1 to 13 and an electrical connector female terminal, characterized in that the female connector terminal comprises an insulating female cap (10) surrounding the insulating male cap (5) of the male connector terminal.

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