High-current plug, power contact for a high-current plug, and shock protection assembly

Abstract

The invention relates to a high-current plug (1) for connection to a mating plug, wherein the high-current plug (1) has: a housing (2) with a base (3); a power contact (4) for establishing contact with a mating contact of the mating plug; and a shock protection assembly (5) that is in particular electrically non-conductive and has a shock protection collar (6) and a shock protection element (7), wherein the power contact (4) is positioned in or on the housing (2) and extends along an axial direction (A), wherein the shock protection assembly (5) is interlockingly or frictionally coupled to the power contact (4), in particular by means of the shock protection element (7).

Description

[0001] Description

[0002] Title for a high-current connector and

[0003] Field of the invention

[0004] The invention relates to a high-current connector, a power contact for a high-current connector and a contact protection assembly.

[0005] State of the art

[0006] To prevent the user from being exposed to contact, high-current connectors require touch protection. This prevents the power contacts of the high-current connector, which is designed as a male connector, for example, from being touched with a hand or finger. The risk of contact arises primarily when the mating connector is not yet plugged in. To verify whether the touch protection is sufficient, a defined test finger or a finger-like test element can be used, which must not touch the power contact.

[0007] In common high-current connectors on the market, this touch protection consists of a touch protection collar that surrounds the power contact and, depending on the application, can also be open on one side (when viewed from above, the touch protection collar then appears U-shaped). In such high-current connectors, the touch protection also includes a touch protection element that surrounds the power contact.

[0008] One solution for implementing the touch protection element is to design it as a part that can be moved along the axial direction. It essentially completely encloses the power contact when not connected to the mating connector. When the mating connector is inserted, the touch protection element is unlocked and moved in such a way that the power contact is released so that it can be contacted by a mating contact of the mating connector.

[0009] Another commercially available solution for the contact protection element is that it is manufactured in one piece with the housing and the power contact already arranged therein during production, e.g. by an injection molding process, thus providing a compact and sealed high-current connector that can be manufactured quickly, easily and cost-effectively in a single injection molding step.

[0010] Disclosure of the invention

[0011] The invention is based on the realization that the design of a movable contact protection element is very complex from a mechanical point of view, since the contact protection must remain securely in its position (contact protection position) when unplugged.

[0012] When the mating connector is inserted, the contact protection element must be reliably unlocked and moved (into a release position). When the mating connector is removed, it must be reliably moved back to its original position (the contact protection position).

[0013] The invention is further based on the recognition that the one-piece production of the high-current connector, particularly when manufactured using an injection molding process, can pose problems, since, for example, the housing walls, housing base, and contact protection element have different wall thicknesses. Without measures in the injection molding process or a special, optimized mold design, this can lead to distortion or incompletely filled areas of the injection mold.

[0014] There may therefore be a need to provide a high-current connector with sufficient touch protection, which is simple and cost-effective to manufacture and in which the touch protection is provided permanently and reliably even during multiple coupling and decoupling processes with a mating connector.

[0015] Advantages of the Invention 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.

[0016] According to a first aspect of the invention, a high-current connector for connecting to a mating connector is proposed.

[0017] The high-current connector has a housing with a base. The high-current connector also has a power contact for contacting a mating contact of the mating connector, as well as a touch protection assembly with a touch protection collar and a touch protection element. The power contact is arranged in or on the housing and extends in an axial direction. The touch protection assembly is coupled to the power contact in a form-fitting or force-fitting manner.

[0018] This advantageously provides particularly robust and permanently reliable touch protection which, particularly when assembled, does not require any moving parts like in the prior art described above. Another advantage is that the high-current connector can be manufactured easily and to a high quality. Different wall thicknesses or material thicknesses between the housing and the touch protection assembly or parts of the touch protection assembly can be easily implemented using simple manufacturing processes. Another advantage is that different power contacts can be used depending on customer requirements, and a touch protection assembly adapted to each of these can be easily provided, so that the same housing can be used modularly for different power contact geometries. This advantageously enables economies of scale in the production of the high-current connector.Another advantage is that the touch protection assembly can be easily replaced if any part of the touch protection element becomes damaged. This advantageously increases the durability of the high-current connector, making it easy to repair.

[0019] For example, it can be provided that the coupling of the touch protection module and the power contact is carried out by means of the touch protection element on the part of the touch protection module.

[0020] The touch protection assembly can, for example, be clipped onto the power contact, locked into place, clamped onto it, or clamped onto it. It can, for example, be designed to be at least partially electrically non-conductive. For example, at least the touch protection element is designed to be electrically non-conductive, at least in sections.

[0021] Preferably, the coupling of the touch protection assembly to the power contact can be achieved without using coupling elements that are designed separately from the touch protection assembly and / or the power contact, such as hose clamp-like or cable tie-like elements that clamp the touch protection assembly to the power contact. In other words, the coupling between the touch protection assembly and the power contact is preferably achieved, for example, by coordinated geometries of the touch protection assembly and the power contact, e.g., complementary geometries.

[0022] Further preferably, the touch protection assembly and the power contact are captively coupled or mounted to one another or connected or attached to one another. This can, for example, be a coupling that can be removed without causing damage.

[0023] Preferably, the touch protection assembly can be manufactured separately from the housing and the power contact, for example. This advantageously results in particularly cost-effective and simple production of the high-current connector. Different wall thicknesses between the housing and the touch protection element on the power contact can also be easily implemented.

[0024] The contact protection assembly can be designed as an injection-molded part, for example. This allows for simple and cost-effective production.

[0025] The touch protection element can be arranged, for example, at a free end of the power contact. This advantageously and reliably prevents contact with the power contact from above (along the axial direction).

[0026] It can be provided, for example, that the touch protection element at the free end of the power contact tapers in a wedge shape starting from the power contact and along the axial direction. A wedge shape can be understood, for example, to mean that the wall thickness at the free end of the touch protection element decreases from the power contact towards the end. The transition from the greater wall thickness to the lesser wall thickness can be linear, for example, but it can also be convex or concave. It can, for example, be parabolic. This advantageously enables particularly easy mating with the mating connector. In particular, suitable shaping can ensure that the mating force does not increase suddenly when mating the mating connector with the high-current connector.

[0027] For example, it can be provided that the power contact contains copper, especially a predominantly copper component. This advantageously achieves a particularly high current-carrying capacity with a small volume or small dimensions of the power contact.

[0028] Alternatively or additionally, it can be provided, for example, that the contact protection element and / or the contact protection collar is made of an electrically non-conductive plastic and in particular comprises or has PBT (polybutylene terephthalate) or PA (polyamide), e.g. PA6 or PA66, glass fiber filled or without glass fiber admixture, in particular PBT in VO quality, or comprises or has a predominant proportion. This advantageously results in particularly good electrical insulation. VO quality PBT can particularly advantageously provide particularly good flame protection. This is advantageous because the power contact can heat up considerably when high currents are transmitted.

[0029] It is understood that the contact protection collar can be manufactured in one piece with the contact protection element.

[0030] The high-current connector or power contact can be provided or configured or used as a high-current connector or power contact for vehicle applications, e.g., for automobiles. It can be, for example, a high-current connector or power contact for high-voltage applications (e.g., at least 42 V, preferably at least 100 V, particularly preferably at least 200 V) and / or a high-current connector or power contact for high-current applications (e.g., for currents of more than 1 A, more than 10 A, or more than 50 A). An electrical line of the high-current connector or power contact can, for example, have a cross-section of at least 1 mm 2 or at least 5 mm 2 or at least 10 mm 2 or at least 50 mm 2The power contact can, for example, be designed to permanently transmit such currents or power. The term "comprise" is used synonymously with the term "have," unless otherwise stated.

[0031] In a further development, it is provided that the contact protection collar surrounds the power contact at least in sections in a circumferential direction surrounding the axial direction. This ensures a particularly high level of contact protection.

[0032] For example, it can be provided that the contact protection collar extends around the power contact over a total of at least 180°. This further increases the level of contact protection. A total of at least 180° can be understood, for example, as meaning that along the direction of rotation (which covers a 360° angular range), at least 180° are covered by the contact protection collar, either in one piece or across several segmented sections. It can be formed, for example, from three sections spaced apart at 60° each, or from four sections spaced apart at least 45° each, or similarly.

[0033] In a further development, it is provided that the touch protection collar is spaced apart from the power contact and / or the touch protection element, so that a mating contact of the mating connector can be arranged between the touch protection collar and the power contact and / or the touch protection element for electrically contacting the power contact. This advantageously ensures that the mating connector or mating contact can be easily contacted with the power contact. Furthermore, the touch protection collar and / or the touch protection element can advantageously provide mechanical support for the mating connector. Furthermore, the touch protection collar can guide the mating of the mating connector and the high-current connector, thus simplifying correct positioning.Furthermore, it can be advantageously achieved, in particular if the contact protection collar is spaced apart from the power contact and / or the contact protection element at all points, that the contact protection collar is not in direct electrical contact with the power contact and thus the contact safety is further improved, e.g. if moisture or particles have deposited on the contact protection collar and / or the contact protection element.

[0034] Alternatively or additionally, the touch protection element is provided adjacent to the power contact, in particular, it touches the power contact. This advantageously ensures that the touch protection element is arranged particularly close to the power contact, making it difficult to bypass the touch protection. The touch protection element can, for example, be arranged closer to the power contact than the touch protection collar. It can thus represent the last barrier against contact with the power contact, for example, when approaching from the outside after overcoming the touch protection collar.

[0035] In a further development, the contact protection collar and the contact protection element are integrally connected to one another. They can be formed as a single piece, in particular, they cannot be separated from one another without causing damage.

[0036] This provides a particularly easy-to-manufacture and / or handle touch protection assembly. The touch protection assembly, in particular the touch protection collar and touch protection element, can be formed as a single piece, particularly in a manner that cannot be disassembled without damage.

[0037] The contact protection collar and the contact protection element can be connected to each other, for example, by a connecting section running in the radial direction.

[0038] They can, for example, be made from a common material. They can, for example, be manufactured in a single manufacturing step, such as an injection molding process or a 3D printing process.

[0039] The contact protection collar and the contact protection element (with the exception of the connecting section) can be spaced apart from each other, preferably along the entire circumference. The spacing can be configured, for example, in the radial direction.

[0040] In a further development, it is provided that the power contact is led through the bottom of the housing to a contact side of the housing.

[0041] This results in a particularly stable coupling of the power contact or the power contact assembly or the power contact unit with the housing.

[0042] For example, it can be provided that the power contact is electrically connected to an electrical line on a side of the base facing away from the contact side. The electrical line can be designed, for example, as a (flexible) cable or, for example, as a rigid line, such as a busbar (cable rail). This side of the base can be referred to, for example, as the connection side. This advantageously separates a connection end or connection area of ​​the power contact from a contact area of ​​the power contact for a mating contact element of the mating connector.

[0043] In a further development, it is provided that the contact protection module has a module base with an opening, wherein the power contact is guided through the opening.

[0044] This advantageously enables a defined position of the power contact after mounting the touch protection assembly on the housing. Another advantage is that mounting can be carried out via the power contact without damaging the touch protection assembly, which ensures particularly reproducible stability in the mounted state.

[0045] The assembly base can, for example, essentially completely surround the power contact with the edge of the opening. This protects the power contact from contact even at its lower end within the housing. Another advantage is that the contact protection assembly is particularly stable.

[0046] In principle, an embodiment is also conceivable in which the contact protection element is L-shaped (e.g. with an upper wall at a free end of the

[0047] power contact and a side wall on the power contact) or e.g. U-shaped (e.g. with an upper wall at a free end of the power contact and two side walls on the power contact).

[0048] For example, if the contact protection element has two side walls, these two side walls may not be connected to each other by means of a component base, but rather have free ends. With a single side wall (e.g., L-shaped), it may also be possible to provide no component base.

[0049] For example, in the case of an L-shaped or U-shaped touch protection element, projections or stubs pointing radially inwards (towards the power contact) can be provided on one or both side walls. These projections or stubs can be fork-shaped, i.e., spaced apart from one another. They can be designed, for example, in such a way that they accommodate the power contact between them. The touch protection element can thus be guided or held on the power contact, for example. In principle, it is also possible for only a single stub or projection (pointing towards the power contact) to be provided on a side wall.

[0050] Alternatively or additionally, the touch protection element covers a free end of the power contact. This advantageously prevents contact with the power contact or its free end when approaching along the axial direction. Furthermore, damage to the power contact or its free end when mating with the mating connector is advantageously prevented. If the touch protection element is damaged, the touch protection assembly can be easily and cost-effectively replaced.

[0051] The free end of the power contact can be, for example, a distal end in the axial direction of the power contact.

[0052] Alternatively or additionally, the touch protection element is connected to the assembly base. This advantageously provides a particularly stable touch protection assembly.

[0053] The contact protection element can be formed directly or immediately with the assembly base or connected to it.

[0054] The assembly base and the contact protection element can be integrally connected or formed as a single piece. They can be connected in such a way that they cannot be separated without damaging each other.

[0055] The contact protection element can, for example, protrude from the assembly base, e.g. essentially parallel to the axial direction.

[0056] In a further development, it is provided that the touch protection element has a guide structure, in particular a groove or a projection, on its side facing the power contact, wherein the power contact and the touch protection element can be positioned in a defined position relative to one another during assembly by means of the guide structure. This advantageously ensures particularly reliable touch protection. A lateral (radial) projection and / or axial projection of the power contact beyond the touch protection assembly, in particular beyond the touch protection element, is thereby prevented or the risk of this is reduced. In addition, the assembly of the touch protection assembly is simplified because an assembler only has to place the touch protection assembly correctly on the power contact and then guide it along the power contact using the guide structure until a coupling with the power contact and / or the housing can be effected.This can achieve automatic centering or positioning of the contact protection assembly relative to the housing. For example, the guide structure can extend substantially along a side wall of the contact protection element. The guide structure can extend substantially along the entire side wall (e.g., viewed in the axial direction). However, it can also be provided that the guide structure extends only along a portion, e.g., the lower part of the side wall.

[0057] The guide structure can, for example, run parallel to the axial direction or, for example, provide guidance parallel to the axial direction. It can also, for example, clamp the power contact at the end of the assembly path, e.g., in the radial direction, e.g., at the lower end or in the base area of ​​the contact protection assembly.

[0058] Alternatively or additionally, it is provided that the touch protection element has a further guide structure at a front end, which is coupled to a free end of the power contact, in particular such that the touch protection element is held stationary in the radial direction relative to the power contact, in particular in the region of the free end of the power contact. This advantageously ensures that the touch protection assembly is held in the correct position on the power contact. Preferably, radial misplacement between the power contact and the touch protection element or touch protection assembly is thereby prevented or at least limited to a small area. The touch protection, in particular also with regard to an axial approach to the power contact, is reliably and permanently ensured.

[0059] The further guide structure can be designed, for example, as a recess and / or groove in the front end of the contact protection element. Alternatively or additionally, it can also be designed as at least one collar element or at least one apron which projects from the front end of the contact protection element in the direction of the power contact. Such a collar element or such an apron (or a plurality of these elements) can overlap with the power contact. In principle, it is also conceivable for the further guide element to be designed as a type of projection or as a pin or as a bolt which, for example, couples to a power contact recess on an end face of the power contact, e.g. engages in such a recess.

[0060] In a further development, the touch protection module has at least one module locking element that can be locked into a power contact undercut of the power contact. This allows the touch protection module to be easily mechanically coupled to the power contact or secured to it.

[0061] The module locking element can be designed, for example, as a type of locking hook or locking lance with a projection (in particular facing the power contact).

[0062] For example, it can be provided that the assembly locking element is formed in, on, or from a side wall of the contact protection element. For example, the assembly locking element can be part of the side wall of the contact protection element or can be cut out of the side wall of the contact protection element. This allows the contact protection element or the contact protection assembly to be designed particularly compactly and simply.

[0063] For example, it can be provided that the assembly locking element is elastically and reversibly displaceable relative to the side wall of the contact protection element. This enables particularly simple, quick, and reliable installation of the contact protection assembly on the power contact. After installation on the power contact, the contact protection assembly can, in particular, be arranged captively on the power contact or coupled to it. In principle, this also makes it particularly easy to remove the contact protection assembly from the power contact (e.g., using an unlocking or unlatching tool).

[0064] Alternatively or additionally, the touch protection assembly has at least one assembly undercut that can be locked into a power contact locking element of the power contact. This allows the touch protection assembly to be easily mechanically coupled to the power contact or secured to it.

[0065] The power contact locking element can be designed, for example, as a projection that projects laterally. It can be provided, for example, that the assembly undercut is formed in, on, or from a side wall of the contact protection element. For example, the assembly undercut can be part of the side wall of the contact protection element or can be cut out of the side wall of the contact protection element. It can be designed, for example, in the manner of a tab or an eyelet. Alternatively or additionally, it can be designed as a recess. This allows the contact protection element or the contact protection assembly to be particularly compact and simple.

[0066] For example, it can be provided that the assembly undercut is elastically and reversibly displaceable relative to the side wall of the contact protection element. It can be designed, for example, as a type of locking lance, wherein, instead of a locking projection or hook, a recess and / or an eyelet or the like is provided, which can couple with the power contact locking element.

[0067] In a further development, the touch protection assembly is designed with mirror symmetry and / or point symmetry. This advantageously makes the touch protection assembly very easy to install, as it can be mounted on the housing rotated by 180° around the axial direction, for example.

[0068] A mirror plane can be, for example, a plane that extends parallel to the axial direction and, for example, passes through the center of the touch protection assembly. One or more mirror planes can be present. A mirror point for point symmetry can, for example, be located at the center of the touch protection assembly.

[0069] In a further development, it is provided that the base of the housing has a base that protrudes from the base, in particular in the axial direction, wherein the touch protection assembly is mounted on the base or rests on the base or is arranged on it. This advantageously enables a particularly deep immersion of the power contact into the mating connector. Furthermore, the base can advantageously provide a particularly good mechanical hold for a mating connector. Furthermore, the base can advantageously represent a defined axial stop for the touch protection assembly. This enables the touch protection assembly to be mounted until it rests on the base or is mounted on the base; further axial displacement into the interior of the housing is no longer possible. This prevents damage to the touch protection assembly, e.g.of the touch protection element, which could potentially be subjected to excessive pressure from the distal end of the power contact if it were to be displaced further in the axial direction. Another advantage is that by resting or sitting on the base, the touch protection assembly can be clamped to the power contact (e.g., in the axial direction), e.g., if it is coupled to the power contact via a clip connection. The base also has the advantage that the touch protection assembly can be constructed particularly compactly in the axial direction, thereby increasing its stability compared to mounting or arranging it on the floor or at the lowest point of the housing.

[0070] In a further development, the contact protection element extends at least partially along a side wall of the power contact. This advantageously further improves contact protection.

[0071] In a further development, it is provided that the power contact is designed as a flat contact, wherein the contact protection element encloses the power contact in a U-shape, wherein in particular the legs of the contact protection element running along the axial direction are formed on the narrow sides of the flat contact.

[0072] This advantageously ensures that the wide sides (or at least one of the wide sides) of the flat contact, which are usually used for contacting, remain essentially free, while at the same time providing good contact protection on the narrow sides. This can be advantageous, for example, if the power contact is contacted by a counter-power contact or counter-contact of the mating connector not along the axial direction (so-called 180° offset), but along a radial direction running transversely thereto (so-called 90° offset). In this case, for example, the narrow side or one of the narrow sides can be assigned to the mating connector.

[0073] For a flat contact, for example, a ratio between the dimensions of the wide side and the narrow side in the range of 2:1 to 30:1 can be provided.

[0074] In a further development, it is provided that the high-current connector, in particular the housing, has a plug-in collar for mechanical coupling with the mating connector, wherein the plug-in collar is arranged radially outside the contact protection assembly. This advantageously results in a particularly secure, permanent and robust connection of the high-current connector with the mating connector. Furthermore, functional separation can advantageously be achieved. The plug-in collar can, for example, absorb the forces that occur, for example, during the plugging process or in the event of vibration loads or shaking of cables. It can also provide a hold or bearing for assembly aids such as operating elements (levers and / or sliders). The plug-in collar can be designed alternatively or additionally to seal the plug connection. A seal, e.g. a circumferential radial seal, can be arranged, for example, on its inside and / or outside.This can then interact with a wall or a collar of the mating connector. The touch protection assembly, on the other hand, can be designed primarily to prevent contact with the power contact. For this purpose, it can, for example, have a thinner wall than the plug collar and / or the housing. This allows the individual elements (the housing with plug collar and base on the one hand, and the touch protection assembly on the other) to be specifically optimized for their individual functions in terms of material selection, material thickness, etc., so that the high-current connector can be provided in a particularly robust, suitable for everyday use, and cost-effective manner.

[0075] For example, the plug-in collar can be arranged radially outside the contact protection collar. This creates a particularly stable and user-safe design, reducing the risk of damage to the contact protection components (contact protection assembly and / or contact protection collar) if the high-current connector is dropped.

[0076] In a further development, the contact protection element has at least one projection that extends beyond a contact surface of the power contact. This advantageously ensures that the mating connector coupled or connectable to the high-current connector cannot be brought too close to the contact surface of the power contact. In such a case (without a projection), the contact blades of the mating contact element, which are often provided in a mating contact element of the mating connector, can be compressed too tightly (on one side of the power contact) or can be positioned too far away from the power contact (on the other side of the power contact).

[0077] For example, it can be provided that the at least one projection is designed as a stop for the mating connector.

[0078] For example, it can be provided that the at least one projection is arranged on a side wall of the contact protection element or on a leg of the contact protection element. The projection can extend, for example, along the entire side wall or only along a section of the side wall, e.g., in a lower section, e.g., the lower 75% or the lower 50% of the side wall. The projection or stop can protrude, for example, by at least 0.5 mm or by at least 1 mm beyond the contact surface of the power contact.

[0079] The projection can, for example, protrude beyond the contact surface of the power contact in a radial direction. The projection can, for example, protrude beyond the contact surface of the power contact approximately parallel to a surface normal to the contact surface of the power contact.

[0080] For example, it can also be provided that a projection is provided on each side of the side wall. In other words: if, for example, the power contact is designed as a flat contact with two contact surfaces facing away from each other, a projection can be formed for each contact surface on the side wall of the contact protection element, so that a stop is formed on both sides.

[0081] According to a further aspect of the invention, a power contact for a high-current connector is proposed.

[0082] The power contact has a, in particular electrically non-conductive, touch protection assembly with a touch protection collar and a touch protection element, wherein the touch protection assembly is positively or non-positively coupled to the power contact.

[0083] This advantageously provides a particularly safe power contact. Another advantage is that the touch protection in the form of a touch protection assembly can be particularly easily connected or coupled to the power contact.

[0084] According to a further aspect of the invention, a contact protection assembly is proposed.

[0085] The touch protection assembly is designed for mounting on a power contact of a high-current connector. The touch protection assembly comprises a touch protection collar and a touch protection element and is designed to be positively or non-positively coupled to the power contact, in particular without being permanently connected or coupled to another part of the high-current connector. Drawings

[0086] 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.

[0087] It shows

[0088] Fig. 1 : a schematic cross section through a

[0089] High-current plug with a power contact and a touch protection element from the state of the art;

[0090] Fig. 2: a schematic perspective view of a

[0091] High-current plug with a power contact and a touch protection element from the state of the art;

[0092] Fig. 3: a schematic perspective view of a

[0093] High-current connector with a touch protection assembly;

[0094] Fig. 4: a schematic perspective view of a

[0095] Touch protection assembly.

[0096] Figure 1 shows a schematic cross section through a high-current connector 1 with a power contact 4 and a contact protection element 7 from the prior art.

[0097] This high-current connector 1 for connecting to a mating connector (not shown here) has a housing 2 with a touch protection collar 6 and a power contact 4 for contacting a mating contact of the mating connector. The power contact 4 is arranged in the housing 2 and extends along an axial direction A. The touch protection collar 6 surrounds the power contact 4 at least in sections in a circumferential direction U running around the axial direction A. The high-current connector 1 has a touch protection element 7 for the power contact 4, wherein the touch protection element 7 is designed to be displaceable along the axial direction A and surrounds the power contact 4 like a knife sheath. As long as no mating connector is plugged in - as shown in Fig. 1 - the touch protection element 7 is in a touch protection position.When plugging in the mating connector, the contact protection element 7 can be moved downwards (into a releasing position) and releases the power contact 4.

[0098] Viewed in a radial direction R perpendicular to the axial direction A outside the contact protection collar 6, the housing 2 further comprises a plug-in collar 19 with which the mating connector can be mechanically coupled.

[0099] The power contact 4 extends through a base 3 of the housing 2 to a contact side 9 of the housing 2, where it can be contacted with the mating contact of the mating connector. On a connection side 20 of the housing 2 facing away from the contact side 9 of the base 6, the power contact 4 can be connected to an electrical line (not shown here).

[0100] Furthermore, Fig. 1 shows a test element 30 whose shape and size mimic a human finger. The high-current connector 1 is designed such that it is not possible for the test element 30 to touch an electrically conductive surface or an electrically conductive section of the power contact 4. This is indicated by two different positions of the test element 30. When the test element 30 approaches from above (parallel to the axial direction A), the test element 30 encounters a section of the contact protection element 7, which surrounds the power contact 4 on both sides like a knife sheath and projects beyond a distal free end 12 of the power contact 4. The test element 30 cannot therefore penetrate to an electrically conductive part of the power contact 4. When approached obliquely from above, the test element 30 encounters lateral walls of the knife-sheath-shaped contact protection element 7.

[0101] Figure 2 shows another high-current connector 1 from the prior art in a schematic perspective view.

[0102] The power contact 4 is designed here as a flat contact 17. The

[0103] The touch protection element 7 is formed integrally with the housing 2 as a common injection-molded part and surrounds the power contact 4 in an arched manner at its free end 12 and at its two narrow sides 18. The wide sides 22 of the flat contact 17 are open and can be contacted with a mating contact of the mating connector. The touch protection collar 6 extends parallel to the axial direction A approximately to the free end 12 of the power contact 4 or even projects slightly beyond it. The touch protection collar 6 surrounds the power contact 4 in a U-shape and is open on one of its narrow sides. A gap is formed between the touch protection collar 6 and the power contact 4, which is narrower than a typical human finger or the test element 30. In this way, sufficient touch protection is achieved. The power contact 4 projects through the base 3 of the housing 2.

[0104] Figure 3 shows a schematic perspective view of a high-current connector 1 for connecting to a mating connector (not shown).

[0105] The high-current connector 1 has a housing 2 with a base 3. It also has a power contact 4 for contacting a mating contact (not shown) of the mating connector and a, in particular electrically non-conductive, touch protection assembly 5 with a touch protection collar 6 and a touch protection element 7. The power contact 4 is arranged in or on the housing 2 and extends along an axial direction A. The touch protection assembly 5 is coupled to the power contact 4 in a form-fitting manner (e.g. in the manner of a clip connection) or in a force-fitting manner (e.g. by a type of clamp connection). For example, this coupling can be effected with a side wall 16 of the power contact 4. The housing assembly 5 can, as shown here, be clipped onto the power contact 4 or locked to the power contact 4.The coupling between the power contact 4 and the touch protection assembly 5, which has the touch protection collar 6 and the touch protection element 7, is carried out here, for example, by the touch protection assembly 5 using the touch protection element 7.

[0106] A radial direction R runs perpendicular to the axial direction A, a circumferential direction U runs around the axial direction A.

[0107] The base 3 of the housing 2 here has - purely by way of example - a base 15 which, here by way of example, protrudes from the base 3 in the axial direction A. In this exemplary embodiment, the contact protection assembly 5 is mounted on the base 15 or sits on the base 15 or is arranged on the base 15. The base 15 can be viewed as part of the base 3 and represent a type of projection of the base 3. The base 15 can also be an element which rises above the continuous base 3, for example.

[0108] Mounting on the base can be understood here, for example, as meaning that the touch protection assembly 5 rests on the base 15 with an assembly base 10 or touches the base 15. This provides a kind of stop position for the touch protection assembly 5, ie: the touch protection assembly 5 cannot be displaced parallel to the axial direction A toward the base 3 of the housing 2 or toward the base 15 further than the base 15.

[0109] It is fundamentally possible for the housing 2 not to have a base 15. In this case, the contact protection assembly 5 can be mounted on the base 3 of the housing 2 or can rest on the base 3.

[0110] The high-current connector 1, in particular the housing 2, has, for example, a plug-in collar 19, which can be designed, for example, for mechanical coupling to the mating connector and / or for supporting or attaching an actuating element such as a slider and / or a lever. The plug-in collar 19 is arranged, for example, outside the contact protection assembly 5 in the radial direction R. The plug-in collar 19 is arranged, for example, outside the contact protection collar 6, viewed in the radial direction R.

[0111] The contact protection element 7 is arranged here, for example, entirely within the contact protection collar 6. In other words: the contact protection collar 6 surrounds the contact protection element 6 in the direction of rotation U. In other words, the contact protection collar 6 is located radially outside the contact protection element 7.

[0112] The contact protection assembly 5 is designed as a single-piece element. It cannot be disassembled into its individual components without causing damage.

[0113] In particular, the contact protection collar 6 and the contact protection element 7 are integrally connected to one another. The contact protection collar 6 and the contact protection element 7 are connected to one another, for example, by a connecting section 8 extending in the radial direction R. The connecting section 8 is designed here, for example, as an assembly base 10 or is designed as a part (section) of the assembly base 10. In principle, the connecting section 8 can also be spaced apart from the assembly base 10, viewed in the axial direction.

[0114] The power contact 4 extends through the base 3 of the housing 2 to a contact side 9 of the housing 2, where it can be contacted with the mating contact of the mating connector. On a connection side 20 of the housing 2 facing away from the contact side 9 of the base 3, the power contact 4 can be connected to an electrical line (not shown here).

[0115] In this embodiment, the touch protection module 5 has at least one module locking element 13 (here, for example, one module locking element 13 is provided on each of the two side walls 27 of the touch protection element 7). The module locking element 13 can be designed, for example, as a locking lance 31 with a free end. A locking lug 32 or locking projection can be formed at the free end, for example, which faces the power contact 4. The at least one module locking element 13 (here: each module locking element 13) can be locked to a power contact undercut 14 of the power contact 4.

[0116] The two assembly locking elements 13 are formed here, for example, in or from the side wall 27 of the contact protection element 7. They are cut out of the respective side wall 27 of the contact protection element 7 or are injection-molded.

[0117] The two assembly locking elements 13 are designed here, for example, to be elastically and reversibly displaceable relative to the side wall 27 of the touch protection element 7. Thus, when mounting the touch protection assembly 5 on the power contact 4, they can simply spring radially outward and then spring into the power contact undercut 14. This enables particularly simple and reliable assembly.

[0118] In an embodiment not shown here, it can be provided that the contact protection module 5 has at least one module undercut that can be locked to a power contact locking element of the power contact 4. It can be provided that the at least one module undercut is formed in, on, or from a side wall 27 of the contact protection element 7; it can be designed, for example, in the manner of a tab or an eyelet.

[0119] It can be provided, for example, that the assembly undercut is elastically reversibly displaceable relative to the side wall 27 of the contact protection element 7, e.g. in the manner of a locking lance, wherein a tab or eyelet or the like is formed on this locking lance, e.g. in the region of its free end.

[0120] The power contact locking element can be designed as a projection, for example on a side wall 16 of the power contact 4. The projection can be designed rigidly, for example, but it can also be designed to be resilient radially inward into the power contact 4.

[0121] As described above, the touch protection assembly 5 has the assembly base 10, which has an opening 11. The power contact 4 is guided through the opening 11. The touch protection element 7 covers the free end 12 of the power contact 4 with a front end 25. The touch protection element 7 is connected here, for example, to the assembly base 10, here, for example, integrally connected to the assembly base 10.

[0122] The contact protection element 7 runs at least in sections along a side wall 16 of the power contact 4.

[0123] The power contact 4 is designed here, for example, as a flat contact 17 (although, of course, a round contact or the like is also conceivable), with the touch protection element 7 enclosing the power contact 4 in a U-shape or like an archway. Here, for example, the legs of the touch protection element 7 running along the axial direction A are formed on the narrow sides 18 of the flat contact 17.

[0124] The touch protection element 7 has a guide structure 23 on its side facing the power contact 4, here for example a groove 24. The power contact 4 and the touch protection element 7 can be positioned in a defined position relative to one another during assembly by means of the guide structure 24. In principle, the guide structure 23 or the groove 24 can be dispensed with. Here, for example, the guide structure 23 or groove 24 is only formed in the lower part of the side wall 27 (beneath the locking lance 31). In other embodiments, it can also extend further upwards, for example. It can also be continued in the locking lance 31, for example. The guide structure 23 can here, for example, be coupled to a projection at the lower end of the power contact 4, so that the touch protection assembly 5 is arranged or fixed or secured at its lower end in a defined position relative to the power contact 4.has only a small tolerance and at the same time is easy to mount on the power contact 4, e.g. by plugging it onto the power contact 4.

[0125] The touch protection element 7 has at its front end 25 a further guide structure 29 which couples to the free end 12 of the power contact 4. This coupling can be designed, for example, such that the touch protection element 7 is held stationary relative to the power contact 4 in the radial direction R. The further guide structure 29 can be, for example, a collar element projecting downwards from the front end 25 of the touch protection element 7 or a downwardly projecting apron. Preferably, two collar elements or aprons are provided which encompass the power contact 4 from both sides or overlap with it or its front or free end 12.

[0126] Alternatively or additionally, it can be provided that the front end 25 of the touch protection element 7 has a receptacle 26 on its inner side facing the free end 12 of the power contact 4, here e.g. in the form of a recess. The free end 12 of the power contact element 4 is received in the receptacle 26 when the touch protection assembly 5 is assembled. This prevents radial displacement of the power contact 4. At the same time, the power contact 4 supports the front end 25 of the touch protection element 7 and thus also the touch protection assembly 5. This simplifies and makes it more reliable to install the touch protection assembly 5 on or in the housing 2, and also improves the robustness of the high-current connector 1. Such a receptacle 26 can represent the further guide structure 29, be a part of it, or supplement it.

[0127] The power contact 4 here, for example, has copper as its material, in particular to a predominant extent.

[0128] The contact protection assembly 5 is made, for example, of an electrically non-conductive plastic, preferably a flame-retardant plastic. It can be made of, for example, PBT (polybutylene terephthalate) or PA (polyamide), e.g., PA6 or PA66, glass fiber-filled or without glass fiber admixture, in particular PBT in V0 quality, especially in a predominant proportion. It can be manufactured, for example, as an injection-molded component or using a 3D printing process or the like.

[0129] The touch protection collar 6 surrounds the power contact 4 at least in sections along or in the circumferential direction U, in particular along a total of at least 180°. In Fig. 3, in conjunction with Fig. 4 (here, however, without the power contact 4), it is clearly visible that the touch protection collar 6, as part of the touch protection assembly 5, surrounds the power contact 4 in a U-shape and encloses it on three sides, so that contacting of the power contact 4 from the side is possible (90° insertion) as well as insertion parallel to the axial direction A (180° insertion).

[0130] The touch protection collar 6 extends, viewed along the axial direction A, preferably approximately to the height of a free end 12 of the power contact 4. Here, the touch protection collar 6 even projects slightly beyond the free end 12 of the power contact 4 (e.g., a few millimeters) and ends slightly below the highest point of the touch protection element 7 (viewed in the axial direction A, on the side facing away from the base 3).

[0131] The touch protection collar 6 is spaced from the power contact 4 and, here by way of example, also from the touch protection element 7. A gap is formed between the touch protection collar 6 and the power contact 4 and, here by way of example, also between the touch protection collar 6 and the touch protection element 7. A mating contact of the mating connector can be arranged or inserted between the touch protection collar 6 and the power contact 4 or the touch protection element 7 to make electrical contact with the power contact 4. At the same time, the gap is so small (e.g., a few millimeters) that it is not possible to touch the power contact 4 with a finger. A finger does not fit in the gap. At the same time, the touch protection element 7 prevents the finger from striking the front side or the distal end or the free end 12 of the power contact 4.

[0132] The touch protection element 7 is adjacent to the power contact 4, it can touch the power contact 4, for example.

[0133] The touch protection element 7 has, for example, at least one projection 35 that projects beyond a contact surface 36 of the power contact 4, wherein the projection 35 is designed in particular as a stop for the mating connector. Here, for example, two projections 35 are formed on each of the two side walls 27 (which can also be referred to as legs of the touch protection element 7). These projections extend, for example, along the entire height along which the two contact surfaces 36 (front contact surface 36 facing the viewer, rear contact surface 36 facing away from the viewer) are open and are not covered by the touch protection element 7. The projections 35 have a run-up slope at their upper end (which faces the mating connector).The projections 35 are designed to prevent the mating connector from coming too close to the power contact 4, since excessive proximity on one side could potentially damage the contact blades of the mating connector and, under certain circumstances, prevent electrical contact from being established on the other side. The projections 35 extend, for example, approximately parallel to the surface normals of the contact surfaces 36f.

[0134] Figure 4 shows a schematic perspective view of a touch protection assembly 5 with touch protection collar 6, touch protection element 7, and, here as an example, assembly base 10, which also serves as a connecting section 8 between touch protection collar 6 and touch protection element 7. The opening 11 in the assembly base 10 is also clearly visible.

[0135] The contact protection assembly 5 is designed here as a mirror-symmetrical example (in other embodiments it can be designed as a point-symmetrical one).

[0136] The two assembly locking elements 13 can be clearly seen; here they are designed as self-supporting locking lances 31 with locking lugs 32 pointing radially inwards and are exposed from the two side walls 27 of the contact protection element 7.

[0137] The contact protection assembly 5 is designed to be coupled to a power contact 4 in a form-fitting or force-fitting manner, in particular to a power contact 4 of a high-current plug 1.

[0138] The assembly base 10 is also clearly visible.

[0139] The contact protection element 7 is formed here, for example, from two lateral side walls 27 and the front end 25 connecting the two side walls 27, resulting in an arched or U-shaped structure. On the inner side 28 of the rear side wall 27 facing the viewer, the guide structure 23, here in the form of a groove 24, can be seen (above the module base 10). The module locking element 13 is connected to this. On the side of the front end 25 facing the free end 12 of the power contact 4 (not shown here), the receptacle 26, into which the free end 12 can be received, is indicated by dashed lines. In addition, the further guide structure 29 (e.g. in the form of an apron or a cover) arranged on both sides of the front end 25 can be seen.

[0140] Furthermore, the opening 11 in the base 10 is clearly visible. The touch protection assembly 5 can thus be plugged over the power contact 4 and attached to the power contact 4 or coupled to it.

[0141] The power contact 4 or the high-current connector 1 can be provided or designed or used for vehicle applications, e.g., for automobiles, two-wheelers, trucks, boats, aircraft, and the like. It can be, for example, a power contact 4 or high-current connector 1 for high-voltage applications (e.g., at least 42 V, preferably at least 100 V, particularly preferably at least 200 V) and / or for high-current applications (e.g., for currents of more than 1 A, or more than 10 A, or more than 50 A). An electrical line to which the power contact 4 can be connected can, for example, have a cross-section of at least 1 mm 2 or at least 5 mm 2 or at least 10 mm 2 or at least 50 mm2 The power contact 4 or the high-current connector 1 can, for example, be configured to permanently transmit such currents or power.

Claims

1 . High-current connector (1) for connecting to a mating connector, comprising: - a housing (2) with a base (3); - a power contact (4) for contacting a mating contact of the mating connector; - a contact protection assembly (5), in particular an electrically non-conductive one, comprising a contact protection collar (6) and a contact protection element (7); wherein the power contact (4) is arranged in or on the housing (2) and extends along an axial direction (A), wherein the contact protection assembly (5) is positively or non-positively coupled to the power contact (4), in particular by means of the contact protection element (7).

2. High-current plug according to the preceding claim, wherein the contact protection collar (6) surrounds the power contact (4) at least in sections in a circumferential direction (U) surrounding the axial direction (A), in particular along a total of at least 180°.

3. High-current plug according to one of the preceding claims, wherein the contact protection collar (6) is spaced apart from the power contact (4) and / or from the contact protection element (7), so that a mating contact of the mating plug can be arranged between the contact protection collar (6) and the power contact (4) for electrically contacting the power contact (4), and / or wherein the contact protection element (7) is adjacent to the power contact (4), in particular touches the power contact (4).

4. High-current plug according to one of the preceding claims, wherein the contact protection collar (6) and the contact protection element (7) are integrally connected to one another, wherein in particular the contact protection collar (6) and the contact protection element (7) are connected to one another by a connecting section (8) running in the radial direction (R).

5. High-current plug according to one of the preceding claims, wherein the power contact (4) is passed through the bottom (3) of the housing (2) to a contact side (9) of the housing.

6. High-current plug according to one of the preceding claims, wherein the contact protection assembly (5) has an assembly base (10) with an opening (11), wherein the power contact (4) is guided through the opening (11), and / or wherein the contact protection element (7) covers a free end (12) of the power contact (4), and / or wherein the contact protection element (7) is connected to the assembly base (10).

7. High-current plug according to one of the preceding claims, wherein the contact protection element (7) has a guide structure (23), in particular a groove (24) or a projection, on its side facing the power contact (4), wherein the power contact (4) and the contact protection element (7) can be positioned in a defined position relative to one another during assembly by means of the guide structure (24) and / or wherein the contact protection element (7) has a further guide structure (29) at a front end (25) which couples to a free end (12) of the power contact (4), in particular such that the contact protection element (7) is held stationary relative to the power contact (4) in the radial direction (R).

8. High-current plug according to one of the preceding claims, wherein the contact protection module (5) has at least one module locking element (13) which can be locked with a power contact undercut (14) of the power contact (4), wherein in particular the module locking element (13) is formed in or on or from a side wall (27) of the contact protection element (7), wherein in particular the module locking element (13) is elastically reversible relative to the side wall (27) of the contact protection element (7), and / or wherein the contact protection assembly (5) has at least one assembly undercut which can be latched to a power contact latching element of the power contact (4), wherein in particular the assembly undercut is formed in or on or from a side wall (27) of the contact protection element (7), wherein in particular the assembly undercut is elastically reversibly displaceable relative to the side wall (27) of the contact protection element (7).

9. High-current plug according to one of the preceding claims, wherein the contact protection assembly (5) is mirror-symmetrical and / or point-symmetrical.

10. High-current plug according to one of the preceding claims, wherein the bottom (6) of the housing (2) has a base (15) which projects from the bottom (6) in particular in the axial direction (A), wherein the contact protection assembly (5) is mounted on the base (15).

11. High-current plug according to one of the preceding claims, wherein the contact protection element (7) extends at least in sections along a side wall (16) of the power contact (4).

12. High-current plug according to one of the preceding claims, wherein the power contact (4) is designed as a flat contact (17), wherein the contact protection element (7) encloses the power contact (4) in a U-shape, wherein in particular the legs of the contact protection element (5) running along the axial direction (A) are formed on the narrow sides (18) of the flat contact (17).

13. High-current plug according to one of the preceding claims, wherein the high-current plug (1), in particular the housing (2), has a plug-in collar (19) for mechanical coupling with the mating plug, wherein the plug-in collar (19) is arranged in the radial direction (R) outside the contact protection assembly (5), wherein in particular the plug-in collar (19) is arranged in the radial direction (R) outside the contact protection collar (6).

14. High-current plug according to one of the preceding claims, wherein the contact protection element (7) has at least one projection (35) which projects beyond a contact surface (36) of the power contact (4), wherein the projection (35) is designed in particular as a stop for the mating plug.

15. Power contact for a high-current plug, wherein the power contact (4) has a, in particular electrically non-conductive, touch protection assembly (5) with a touch protection collar (6) and a touch protection element (7), wherein the touch protection assembly (5) is positively or non-positively coupled to the power contact (4).

16. Contact protection assembly, designed for mounting on a power contact of a high-current connector, the contact protection assembly comprising: - a contact protection collar (6) and a contact protection element (7); wherein the contact protection assembly (5) is designed to be coupled to the power contact (4) in a form-fitting or force-fitting manner.

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