Electrical connector, opposing electrical connector and connector assembly
The electrical connector design with a protrusion and sliding contact locking device addresses fretting issues by absorbing vibrations, ensuring stable connections in environments with relative terminal movement.
Patent Information
- Application Number
- JP2024094782
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2023-06-16
- Filing Date
- 2024-06-12
- Publication Date
- 2024-12-26
AI Technical Summary
Vibrations in connector systems cause relative movement between conductive electrical terminals, leading to fretting degradation in environments like aviation, which existing spring-damping solutions do not fully address.
An electrical connector design featuring a housing with a protrusion and a connector locking device that allows for sliding contact along the mating axis, preventing form-fit connections perpendicular to the axis, thereby absorbing vibrations and suppressing fretting.
The design effectively prevents relative movement between electrical terminals, maintaining a stable electrical connection by absorbing vibrations and reducing fretting corrosion, suitable for applications in vehicles with movable connectors.
Smart Images
Figure 2024180331000001_ABST
Abstract
Description
[Technical field]
[0001] The present invention relates to electrical connectors, mating electrical connectors, and connector assemblies thereof. [Background technology]
[0002] Connector systems are known that combine an electrical connector with a counter electrical connector to establish an electrical connection. However, in some applications, for example in a vehicle environment such as an aviation environment, vibrations on one or both sides of the connector system can cause relative movement between the conductive electrical terminals, leading to degradation of the terminal interface, known as fretting.
[0003] To combat fretting, some solutions propose connections that absorb and damp vibrations before they reach the electrical connectors, for example by spring-cushioning the mounting of one or both of the electrical connectors. Although the spring-cushioned mounting of the connector system can damp or absorb some of the vibrations and partially mitigate the effects of the vibrations, some relative movement between the electrical terminals still occurs. Summary of the Invention [Problem to be solved by the invention]
[0004] It is therefore an object of the present invention to provide a connector mating solution which further reduces fretting. [Means for solving the problem]
[0005] This object is achieved by an electrical connector according to claim 1. The electrical connector according to the invention comprises a housing and electrical terminals, the housing and the electrical terminals being configured to mate with a mating housing and mating electrical terminals of a counter electrical connector along a mating axis. The housing of the electrical connector comprises a shell at least partially surrounding the electrical terminals, the shell comprising protrusions formed on an outwardly facing surface thereof, the protrusions enabling a form-fit connection with a preferably hook-like latching device of the counter electrical connector along the mating axis. The housing further comprises a connector locking device at least partially surrounding the shell, the connector locking device being in sliding contact with the shell to enable movement of the connector locking device relative to the shell along the mating axis, the connector locking device being configured to prevent a form-fit connection of the latching device with the protrusions, in particular along a direction perpendicular to the mating axis, in a mated state in which the electrical connector and the counter electrical connector are mated.
[0006] Because the connector locking device makes sliding contact with the shell while simultaneously preventing a form-fit connection between the shell and a latching device of a mating electrical connector, the connector locking device can be used to absorb vibrations without transmitting the vibrations to the form-fit connection, thereby inhibiting undesirable fretting. Specifically, the electrical connectors can be mounted in an environment such that the connector locking device receives vibrations from the environment and slides along the shell in response, without affecting the form-fit connection between the connectors along the mating axis.
[0007] In one aspect of the invention, an inwardly facing surface of the connector locking device opposite the outwardly facing surface of the shell can form a receiving space with the outwardly facing surface of the shell, the receiving space having an opening facing toward the protrusion of the shell, and the receiving space configured to at least partially receive the latch device through the opening in a coupled state.
[0008] A receiving space is formed between a surface of the connector locking device and a surface of the shell to prevent undesired movement of the latching device of the opposing electrical connector away from the shell, which could release the form-fit connection when the connectors are fully mated.
[0009] In one aspect of the invention, the inwardly facing surface of the connector locking device can include a first surface portion parallel to the outwardly facing surface of the shell and a second surface portion adjacent the first surface portion on the opening side of the receiving space, the second surface portion being chamfered relative to the mating axis such that the distance between the second surface portion and the outwardly facing surface of the shell gradually increases toward the opening.
[0010] During mating of the connector and mating connector, a chamfered surface portion on the inwardly facing surface of the locking device guides the tip of the latching device received through the opening and bends the tip toward the shell. When fully mated, the latching device contacts the first surface portion. Because the first surface portion is parallel to the outwardly facing surface of the shell, the locking device can slide along the shell without releasing the latching device.
[0011] The present invention also relates to a counter electrical connector according to claim 4. The counter electrical connector comprises a mating housing and mating electrical terminals, which are configured to mate with the housing and electrical terminals of the electrical connector according to one of the above aspects of the invention along a mating axis. The mating housing of the counter electrical connector comprises a mating shell at least partially surrounding the mating electrical terminals and a hook-like latching device, which extends along and is spaced apart from the outwardly facing surface of the mating shell. The latching device comprises a lance extending parallel to the mating axis and a mating projection extending from a face of the lance opposite the outwardly facing surface of the mating shell towards said outwardly facing surface of the mating shell, which allows a form-fit connection with a protrusion of the shell of the electrical connector along the mating axis. The lance of the latch device has one tip fixed to the mating shell, and the second tip of the lance is configured and arranged such that in a mated state, the second tip of the lance is blocked by the connector locking device of the electrical connector, particularly along a direction perpendicular to the mating axis.
[0012] This configuration of the counter electrical connector is particularly suitable for mating with the above-mentioned aspects of the electrical connector of the present invention, since the connector locking device blocks the lance and therefore locks the latch device to the shell and thus the connector to the counter electrical connector. In particular, the lance can be blocked along a direction perpendicular to the mating axis without impeding the sliding movement of the connector locking device along the mating axis while the connectors are in a mated state.
[0013] In one aspect of the invention, the lance of the mating electrical connector can extend perpendicularly from a flange attached to the mating flange of the mating shell. In this configuration, the latching device can be moved from the mating shell of the connector to the flange attached from the outside, facilitating elastic bending of the latching device. Additionally, the use of a flange to provide the lance allows the invention to be realized by reusing standardized mating electrical connectors that already include a mating flange.
[0014] In one aspect of the invention, the latch device can include a notch formed in the second tip on an outwardly facing surface opposite the surface of the lance that faces the outer surface of the mating shell, the notch can facilitate a form-fit of the latch device with the shape of the inwardly facing surface of the connector locking device, e.g., the first parallel surface portion and the second chamfered surface portion of the inwardly facing surface of the connector locking device.
[0015] In one aspect of the invention, the notch can be configured such that a surface of the notch engages the first surface portion in the mated state and / or the surface of the notch is parallel to the outward facing surface of the shell in the mated state, thus improving the form-fit connection between the lance and the connector locking device.
[0016] The object of the present invention is also achieved by a connector assembly according to claim 7. The connector assembly comprises an electrical connector according to any one of the above-mentioned aspects of the electrical connector of the present invention and a counter electrical connector according to any one of the above-mentioned aspects of the counter electrical connector of the present invention. The electrical connector is coupled to the counter electrical connector, and the electrical terminals of the electrical connector abut against the mating electrical terminals, in particular in a plane perpendicular to the mating axis. The projections and the mating protrusions provide a form-fit connection of the latch device and the shell along the mating axis, preventing uncoupling, in particular against the mating direction, and the second tip of the lance is blocked by the connector locking device in a direction perpendicular to the mating axis and away from the shell of the electrical connector.
[0017] When the electrical connector and counter electrical connector are assembled in this configuration, the abutment of the electrical terminal of the electrical connector with the mating terminal of the counter electrical connector is protected and maintained by the connector locking device preventing the latch device from latching to the shell in a form-fit manner. Specifically, movement of the electrical terminal relative to the mating terminal is prevented in one direction along the mating axis M by the abutment of the terminal and in the opposite direction along the mating axis M by the form-fit connection of the latch device with the protrusion. Because the connector locking device has a degree of freedom along the mating axis in sliding contact along the shell of the electrical connector, the connector locking device can absorb vibrations induced externally on the electrical assembly connection, for example by a mounting device, while still ensuring an electrical connection. In this manner, fretting corrosion is inhibited and the quality of the electrical connection is improved.
[0018] In one aspect, a lance of the latching device can be bent toward the shell of the electrical connector by the connector locking device. In particular, the lance of the latching device can be bent toward the shell of the electrical connector by an inwardly facing surface of the connector locking device. By bending the latching device toward the shell, the mating projection is pressed against the protrusion, further strengthening the form-fit connection along the mating axis.
[0019] In one aspect, the form-fit connection between the latch device and the connector locking device may be achieved by planar engagement of the notch and the second surface portion. The parallel shape of the second surface portion relative to the shell face and the matching parallel shape of the notch allow for a form-fit connection that stays in place while at the same time allowing for simultaneous movement of the locking device relative to the shell. Thus, engagement at the interface of the notch and the second surface portion may allow for relative movement along a plane parallel to the mating axis between the connector assembly on the one hand and the connector locking device in contact with the external environment and / or device on the other hand.
[0020] In one aspect, the connector assembly can include a rack for mounting the connector assembly to an external device, particularly a vehicle device, such that the connector assembly has one or more degrees of freedom when mounted on the external device, the electrical connector being disposed in an opening in the rack such that the rack extends partially between a flange of the shell and the connector locking device, the rack is movable relative to the shell and frictionally and / or positively engages the connector locking device, and the lance remains movably blocked by the connector locking device over a predetermined linear range of relative positions of the rack to the shell along the mating axis.
[0021] In the presence of vibrations in the rack, the connector locking device of the electrical connector vibrates with the rack positively and / or frictionally engaging the connector locking device. However, these vibrations are absorbed by the mobility of the locking device relative to the shell while keeping the lance block in place, and thus the form-fit connection, in place. Thus, the vibrations do not cause relative movement between the electrical terminals, and do not cause relative movement between the shell and the mating shell.
[0022] According to this aspect, the connector assembly is advantageously adapted for rack connection: in fact, the electrical connector can be configured as a mobile connector and can be mounted floating in the rack, i.e. movably relative to the rack.
[0023] The above objects and advantages, as well as further objects and advantages, of the present invention will be more fully understood and appreciated by consideration of the following more particular description of illustrative aspects and embodiments of the invention, the following description being read in conjunction with the accompanying drawings, in which: [Brief description of the drawings]
[0024] [Figure 1] 1 is a perspective view of an electrical connector according to an embodiment of the invention including a rack and a counter electrical connector according to an embodiment of the invention, shown in a separated state; [Figure 2A] FIG. 2 is a perspective view of the electrical connector of FIG. 1 without the rack. [Figure 2B] FIG. 2 is a cross-sectional view of the counter electrical connector of FIG. [Figure 3A] 2 is a cross-sectional view of the electrical connector of FIG. 1 including a rack. [Figure 3B] 2 is a cross-sectional view of the connector locking device of the electrical connector of FIG. 1. [Figure 4A] 2 is a cross-sectional view of the periphery of the connector of FIG. 1 in a first, unmated state of coupling. [Figure 4B] 2 is a cross-sectional view of the outer periphery of the connector of FIG. 1 in a second intermediate state of coupling. [Figure 4C] 1 in a third coupled state; FIG. [Diagram 5] 2 is a cross-sectional view of the connector and rack of FIG. 1 in a coupled state. [Figure 6A] FIG. 6 is an enlarged view of a portion of FIG. 5 in a first vibration state. [Figure 6B] FIG. 6 is an enlarged view of a portion of FIG. 5 in a second vibration state. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0025] In the figures, the same reference signs or numerals used in different figures relate to the same elements unless otherwise indicated in the description. In addition, the embodiments, alternatives, options, variations, completeness and respective features described or described can be freely combined independently of each other.
[0026] FIG. 1 is a perspective view of an electrical connector 1 according to a first embodiment of the invention and a counter electrical connector 101 according to a second embodiment of the invention, before coupling along a mating axis M.
[0027] The electrical connector 1 and the counter electrical connector 101 are adapted to be mated with each other to establish an electrical connection as described below. In the mated state, the electrical connector 1 and the counter electrical connector 101 are assembled in a connector assembly 100 shown in Figure 5 according to a third embodiment of the present invention.
[0028] The electrical connector 1 and the counter electrical connector 101 may be power connectors, in particular high power connectors configured for currents of, for example, 50 A or more. The electrical connector 1 and the counter electrical connector 101 may be configured for power applications in electric vehicles, in particular electric aircraft. The counter electrical connector 101 is mounted on the frame of the vehicle. It may be a fixed, stationary socket connector, and the electrical connector 1 is a mobile, non-stationary plug connector connected to an external device of the vehicle. However, in a variant, the electrical connector 1 may be a fixed connector, the counter electrical connector 101 may be a mobile connector, or both may be mobile connectors. The electrical connector 1 and the electrical connector 101 are both cylindrical in shape, in particular formed cylindrically along the mating axis M. However, the shapes of the connectors 1, 101 are not limited thereto, and the invention is also applicable to connectors having other shapes, for example rectangular parallelepiped shapes.
[0029] To connect the electrical connector 1 to an external device, the electrical connector 1 is mounted in a rack 200 such that the connector 1 has one or more degrees of freedom, as will be further described below. For ease of illustration, the rack 200 is only partially shown here with planar rack walls having a circular shape, although other shapes are possible. As will be further described with respect to FIG. 3A, the housing 3 of the electrical connector 1 is received in a primary rack opening having a diameter larger than the diameter of the shell of the connector 1, and the connector 1 is movable relative to the rack 200 in a direction P, P' perpendicular to the mating axis M to an extent determined by the difference in diameter. Optionally, a resilient device 211 can further help center the housing 3 in the primary rack opening and / or create a friction fit of the connector 1 along the mating axis M.
[0030] Electrical connector 1 includes a housing 3 and electrical terminals 5. Counter electrical connector 101 includes a mating housing 103 and mating electrical terminals 105 that are configured to mate along a mating axis M when connectors 1, 101 are mated along mating axis M. Mating terminals 105 are not visible in Figure 1 but are shown in Figure 2B.
[0031] In the embodiment described herein, the illustrated connector 1 and counter connector 101 each include only one terminal, electrical terminal 5 and mating electrical terminal 105, respectively. However, the present invention is not limited to connectors and connector assemblies that include only one electrical terminal per connector. Instead, the present invention is also applicable to connectors that include a greater number of respective electrical terminals, for example two, three, or four electrical terminals, in each connector that are configured to mate with one another.
[0032] In the following, the electrical connector 1 and the mating electrical connector 101 will be described in more detail with reference to Figures 2A and 2B. Figure 2A is a perspective view of only the electrical connector 1, without the rack 200 of Figure 1. The housing 3 of the connector 1 includes a shell 7, a connector locking device 9, an insulating insert 11, in particular a thermoplastic insulator, and an inner casing 13. The shell 7 surrounds the inner casing 13, i.e., the shell 7 surrounds the outer periphery of the inner casing 13 in a plane perpendicular to the mating axis M. In particular, the shell 7 surrounds the inner casing 13 such that a coupling space 15 is formed therebetween.
[0033] Similarly, the inner casing 13 surrounds the insulating insert 11. The insulating insert 11 is fitted into the inner casing 13, which is fitted into the shell 7. Fig. 2A shows that the electrical terminals 5 are female or socket contact terminals arranged to receive male or plug electrical terminals, and that the electrical terminals 5 are fitted into the insulating insert 11 so that the terminals 5 can receive mating terminals. According to a variant, the electrical terminals 5 may be male contact terminals arranged to receive female electrical terminals.
[0034] The connector locking device 9 surrounds the shell 7, i.e., the connector locking device 9 surrounds the outer periphery of the shell 7 in a plane perpendicular to the mating axis M. However, in accordance with the present invention, the connector locking device 9 is in sliding contact with the shell 7 and is movable relative to the shell 7 along the mating axis M, as will be further described below.
[0035] The shell 7 includes a protrusion 19 on an outwardly facing surface 17 of the shell 7, i.e., the surface opposite the enclosed electrical terminals 5. Specifically, the protrusion 19 is formed along the radial periphery of the shell 7 relative to the mating axis M and protrudes outwardly. Here, the protrusion 19 is formed at a distal tip of the shell 7 along the mating axis M, on a mating surface facing toward a mating counter electrical connector 101, as shown in FIG. 1. The protrusion 19 is configured to provide a form-fit connection with a latching device 109 of the counter electrical connector 101 along the mating axis.
[0036] The shell 7 also includes a flange 21 for mounting the electrical connector 1 to the rack 200 shown in FIG. 1. Here, the flange 21 is not a full circumferential flange, but simply includes three flange portions 23a, 23b, 23c that project outwardly relative to the mating axis M at the same location but at different angular arrangements relative to the mating axis M. For example, here, the flange portions 23a, 23b, 23c project from three different directions, each rotated 120° relative to the other two. The flange portions 23a, 23b, 23c are integrally formed with the remainder of the shell 7. Each flange portion 23a, 23b, 23c includes a respective bore 25a, 25b formed therein and extending parallel to the mating axis M.
[0037] 2B is a cross-sectional view of the mating electrical connector 101 along the mating axis M. The mating housing 103 includes a mating shell 107 and a mating insulating insert 111, in particular a thermoplastic insulator, which here includes an interface insulator 111a, a secondary insulating layer 111b, and a terminal holder 111c. The mating shell 107 surrounds the mating insulating insert 111, i.e., surrounds the outer periphery of the mating insulating insert 111 in a plane perpendicular to the mating axis M. Specifically, the mating shell 107 surrounds the mating insulating insert 111 such that a mating coupling space 115 is formed therebetween.
[0038] The mating insulating insert 111 is fitted into the mating shell 107. FIG. 2B shows that the mating electrical terminal 105 is a female contact terminal, e.g. a male or plug contact terminal configured to be received in the terminal 5. According to an alternative embodiment, the mating electrical terminal 105 may be a female contact terminal configured to receive a male contact terminal. The mating electrical terminal 105 is fitted into the mating insulating insert 111 so that the mating electrical terminal 105 is inserted into the terminal 5 when the electrical connector 1 and the counter electrical connector 101 are mated. To prevent contact of the mating electrical terminal 105, a terminal insulating device 105a is attached distal to the mating electrical terminal 105.
[0039] In variants where the connectors 1, 101 each carry multiple terminals, the rotational positions of the terminals about the mating axis M may be displaced due to the rotational degree of freedom of one or both of the connectors 1, 101. In the case of such angular displacement between the multiple terminals of the connector 1 and the multiple terminals of the connector 101, alignment may nevertheless be facilitated by matching the shapes of the insulating insert 11 and the mating insulating insert 111. In particular, the mating insulating insert 111 may be configured to guide the insulating insert 11 during mating of the housings 3, 103 to readjust the angular positions of the terminals 5, 105. For example, the insulating insert 11 may be provided in a cone shape around the terminals of the electrical connector and the mating insulating insert 111 may be provided in an inverted cone shape around the mating terminals of the opposing electrical connector.
[0040] The mating housing 103 includes a latch device 109. The latch device 109 is hook-shaped and extends along an outward surface 117 of the mating shell 107, i.e., the surface opposite the mating electrical terminal 105. The latch device 109 extends along the outward surface 117 spaced apart from the latch device 109, providing a latch space 113 between the latch device 109 and the outward surface 117.
[0041] The latch device 109 includes a lance 119 extending parallel to the mating axis M and a mating projection 121 protruding from the lance 119. In particular, the mating projection 121 extends from a surface 123 facing the outward surface 117 of the mating shell 107 toward said outward surface 117.
[0042] The mating housing 103 further comprises a flange 125 and the mating shell 107 comprises a mating shell flange 127. The mating shell flange 127 projects radially outward in the circumferential direction relative to the mating axis M, and the flange 125 is attached to the mating shell flange 127, in particular with a form-fit or friction fit. The flange 125 is preferably attached to the mating shell flange 127 by a bolt connection via the flange through-holes 125a.
[0043] The lance 119 extends perpendicularly from the flange 125, with a first tip 129a of the lance 119 fixed to the flange 125 attached to the mating shell 107. The second tip 129b is free and can bend elastically relative to the first tip 129a. The lance 119 extends from the flange 125 such that the second free tip 129b faces the counter electrical connector 101 configured to mate with the electrical connector 1. The latch device 109 further includes a notch 131 formed on the outwardly facing surface 133 of the lance 119 between the first tip 129a and the second tip 129b, the function of which will be further described below. The notch 131 is formed closer to the second tip 129b than the mating projection 121.
[0044] Figure 3A is a cross-sectional view of the electrical connector 1 previously described with respect to Figure 2A, now mounted to the rack 200 shown in and described with reference to Figure 1. As can be seen in the cross-sectional view of Figure 3A, the distal tip 47 of the shell 7, facing the side of the electrical connector 1 configured to mate with the counter electrical connector 101, is inwardly chamfered to facilitate guiding the mating shell 107 into the mating space 15 when the electrical connector 1 is mated to the counter electrical connector 101.
[0045] The protrusion 19 includes a second chamfer 27 facing a side of the electrical connector 1 configured to mate with the counter electrical connector 101 and a step 29 facing away from the side of the electrical connector 1 configured to mate with the counter electrical connector 101. The chamfer 27 is configured to facilitate resilient outward bending of the latching device 109 when the electrical connector 1 is mated to the counter electrical connector 101. The step 29 is configured to facilitate latching with the mating protrusion 121 of the latching device 109.
[0046] 3A shows that in this embodiment the inner casing 13 and the shell 7 are separate parts, with the inner casing 13 form-fitting into the shell 7. Specifically, the inner casing 13 is inserted into and received in the shell 7 and is then secured to the shell 7 by a retaining ring or circlip 13a. The inner casing 13 holds terminals 5 configured here as socket terminals with stamped metal strips 5a, known as louver contact bands. The metal strips 5a have parallel louver-like contact bridges along the strips 5a to improve the electrical connection, particularly with regard to the number of contacts and the contact pressure.
[0047] As explained with reference to FIG. 1, the electrical connector 1 is configured to be mounted in the rack 200 by means of a flange 21 including flange portions 23a, 23b, 23c. FIG. 3A is a cross-sectional view of the rack 200, here shown as a rack wall. The rack 200 comprises one primary rack opening 201 for receiving the housing 3, in particular the shell 7, of the electrical connector 1. The diameter D1 of the rack opening 201 is larger than the diameter D2 of the outwardly facing surface 17 of the shell 7, in particular by at least 3%, preferably by more than 6%. The shell 7 of the electrical connector 1 is thus received in the rack opening 201 and may be movable in the rack opening 201. In particular, the electrical connector 1 may be movable in the rack opening 201 rotationally around the mating axis M, translationally along the mating axis M, and / or translationally along at least one direction P perpendicular to the mating axis M.
[0048] The rack 200 further includes a mounting hole 203, the mounting hole 203 being located in a position surrounding the rack opening 201 and coinciding with a position of the bore 25a of the flange portion 23a surrounding the shell row. Specifically, the mounting hole 203 is centrally aligned with the bore 25a when the electrical connector 1 is centrally aligned with the rack opening 201 along the mating axis M. Additionally, the mounting hole 203 has a diameter D4 that is smaller than the diameter D3 of the bore 25a, in particular at least 10% smaller.
[0049] The electrical connector 1 is attached to the rack 200 by pins 205, here three pins matching the number of flange portions 23a, 23b, 23c (only one is visible in FIG. 3A) and the corresponding number of mounting holes 203. The pins 205 are inserted into the bores 25a and the mounting holes 203 such that the flange portion 23a of the housing 3 of the electrical connector 1 is movable along and around the pins 205. The pins 205 have a pin head 205a at a first end and a threaded portion 205b at a second end, the threaded portion 205 being configured to be screwed into a threaded nut 207.
[0050] The electrical connector 1 is mounted in a rack 200 , only a rack wall of the rack 200 is shown in the drawings, disposed and extending between a flange 21 of the housing 3 and a connector locking device 9 of the housing 3 .
[0051] At a first tip, a coil spring 209 is attached to the pin head 205a and wrapped around the pin 205 until it reaches the back surface 21a of the flange 21. The coil spring 209 is placed on the selected pin 205 in a preloaded or compressed state so that the spring bias constantly exerts a force on the back surface 21a of the flange 21 against the pin head 205a.
[0052] Upon stretching, the coil spring 209 presses the flange 21 against the rack 200 along the mating axis M, forming an engagement interface I. Optionally, a resilient device 211, such as a spring or band, can be arranged along the circumferential contour at the location of the pin 205 to center the housing 3 in the rack opening 201 and frictionally engage the rack 200 to the housing 3, specifically to the connector locking device 9, which is in sliding contact along the mating axis M with the shell 7 received in the rack opening 201. In a variant, a different device can be used to positively engage the connector locking device 9 to the rack 200. The connector locking device 9 is annular or ring-shaped and arranged surrounding the shell 7 in sliding contact with the outwardly facing surface 17 of said shell 7, allowing relative movement with respect to the shell 7 along the mating axis M. Specifically, the connector locking device 9 is disposed around the shell 7 such that a receiving space 31 is formed between the outwardly facing surface 17 of the shell 7 and the inwardly facing surface 35 of the connector locking device 9 .
[0053] The connector locking device 9 is shown separately in more detail in FIG. 3B. FIG. 3B is a cross-sectional cutaway view of the connector locking device 9 along a plane collinear with the mating axis M. The diameter D2' of the central opening 37 of the ring-shaped connector locking device 9, defined by the innermost surface 41 of the sliding portion 33 of the connector locking device 9, is selected relative to the diameter D2 such that sliding contact between the connector locking device 9 and the shell 7 is possible. That is, the diameter D2' corresponds to the diameter D2 of the outwardly facing surface 17 of the shell 7 or is 0.1% to 1% larger than the diameter D2.
[0054] The ring-shaped connector locking device 9 includes an inwardly facing surface 35, i.e., a surface that faces toward a central opening 37 of the ring-shaped connector locking device 9 and faces toward the shell 7 disposed in the central opening 37. The inwardly facing surface 35 is configured to form a receiving space 31 together with the shell 7, the receiving space 31 having a receiving opening 39 on the protrusion 19 side for receiving the latch device 109 when the electrical connector 1 and the counter electrical connector 101 are mated.
[0055] The inwardly facing surface 35 comprises a first surface portion 43 and a second surface portion 45. The first surface portion 43 is parallel to the mating axis M and to the outwardly facing surface 17 of the shell 7. The second surface portion 45 adjoins the first surface portion 43 on the side of the receiving opening 39. The second surface portion 45 is chamfered relative to the mating axis M such that the distance between the second surface portion 45 and the mating axis M and the further outwardly facing surface 17 of the shell 7 gradually increases towards the receiving opening 39. A third surface portion 45a can be provided adjacent the second surface portion 43 on the side of the receiving opening 39, the third surface portion 45a being configured to fix the lance 119 in the receiving space 31 and to prevent outward bending of the lance 119.
[0056] Next, the coupling sequence between the electrical connector 1 and the opposing electrical connector 101 will be described with reference to FIGS. 4A, 4B, and 4C.
[0057] 4A is a cross-sectional view of the outer periphery of the electrical connector 1 and the counter electrical connector 101 of FIG. 1 in a first, unmated state of coupling. The electrical connector 1 and the counter electrical connector 101 are aligned opposite to each other along a mating axis M so that the housing 3 and the counter housing 103 can be coupled. Specifically, the electrical connector 1 and the counter electrical connector 101 are aligned such that the mating shell 107 of the counter electrical connector 101 can be inserted into the coupling space 15, and at the same time, the insert casing 13 can be inserted into the mating space 115.
[0058] To facilitate insertion, in this embodiment, the coupling space 15 and the mating coupling space 115 are sized larger than their respective counterparts, i.e., the mating shell 107 and the insert casing 13, e.g., more than 20% larger. In addition, the distal tip 47 of the shell 7 is chamfered inwardly and outwardly to further facilitate mating of the housings 3, 103. For example, this ease of insertion allows the electrical connector 1 and the counter electrical connector 101 to be mated without visual and / or manual access, which may be the case in some applications where the connector 1 is mounted to the rear of a rack. Thus, connector assembly 100 is easier to use than connector assemblies that require visual and / or manual access, such as connector assemblies that require manual actuation, such as connector assemblies that use threaded and / or turn-fastening connections.
[0059] 4B is a cross-sectional view of FIG. 4A in a second intermediate state of the mating sequence. In this second state, the electrical connector 1 and the counter electrical connector 101 move further together along the mating axis M. Specifically, the electrical connector 1 moves toward the counter electrical connector 101 along a direction shown as M1 in FIG. 4B, such that the shell 7 is inserted into the latching space 113 and the mating shell 107 is further inserted into the mating space 15.
[0060] When the shell 7 is further inserted into the latch space 113, the protrusion 19 passes over the mating projection 121. Depending on the mutual alignment of the electrical connector 1 and the counter electrical connector 101, the mating projection 121 can slide along the chamfer 27 of the protrusion 19, and the second free tip 129b of the lance 119 is received in the receiving space 31 through the receiving opening 39 until it abuts against the second surface portion 45. When the connector locking device 9 is pressed in a direction M1 parallel to the mating axis M, for example by pressing the rack 200 and then pressing the connector locking device 9 through the interface I, the tip 129b abuts against the second surface portion 45. Thus, the tip 129b slides along the second surface portion 45 and elastically bends inwardly toward the outward surface 17 of the shell 7.
[0061] In Fig. 4B, the terminals 5, 105 are already abutted as shown in Fig. 5 and a form fit F1 is established as described with respect to Fig. 4C. However, the coupling sequence is not completed because the connectors 1, 101 are not securely coupled. In fact, the elastic restoring force of the lance 119 pushes the connectors 1, 101 back apart and separates them, since the elastic bending of the lance 119 is not stable unless the coupling sequence is completed.
[0062] 4C is a perspective cross-sectional view of FIGS. 4A and 4B in a third mating state of mating. In FIG. 4C, the rack 200 and the engaged connector locking device 9 have moved further along a direction M1 parallel to the mating axis M, and the tip 129b of the lance 119 has slid further along the chamfered second surface portion 45. Thus, the tip 129b resiliently bends further inward toward the outward surface 17 of the shell 7, and the mating projection 119 latches further behind the projection 19 than seen in FIG. 4B.
[0063] Specifically, the mating projection 119 hooks onto the shoulder 29 of the protrusion 19 to provide a first form-fit connection F1. The first form-fit connection F1 locks the hook-like latching device 109 of the counter electrical connector 101 to the shell 7 and prevents the electrical connector 1 and the counter electrical connector 101 from moving apart along the mating axis M.
[0064] FIG. 4C also shows that the tip 129b has slid over the second surface portion 45 towards the first surface portion 43 adjacent to the second surface portion 45 and extending parallel to the mating axis M. A notch 131 formed in the outwardly facing surface 133 of the lance 119 engages with the first surface portion 43 such that a second form-fit connection F2 is realized. In particular, the notch 131 has a shape corresponding to the parallel first surface portion 43, i.e. a shape that allows a plane parallel to the face 17 of the shell 7 when the lance 119 is bent inwardly. The second form-fit connection F2 blocks the second tip 129b in a direction P perpendicular to the mating axis M, away from the shell 7 of the electrical connector 1. The second form-fit connection F2 thus prevents the return of the bent lance 119 to its rest position and the release of the first form-fit connection F1. However, the second form-fit connection F2 does not prevent translational movement of the connector locking device 9 and the shell 7 along the mating direction.
[0065] The inventive advantages of the present invention and in particular of the above exemplary embodiment are further explained in view of Figures 5, 6A and 6B. Figure 5 is a cross-sectional view of an electrical connector 1 mounted on a rack 200 and mated to a counter electrical connector 101 in a coupled state as partially shown in Figure 4C. Figure 5 therefore also shows a connector assembly 100 according to a third embodiment of the present invention.
[0066] In the coupled state, the housing 3 and the mating housing 103 are fitted together such that the electrical terminals 5 abut against the mating electrical terminals 105. The insert casing 13 is received in the mating coupling space 115, and the mating shell 107 is received in the coupling space 15. In addition, the electrical terminals 5, 105 are in complete contact with each other at the engagement surface E. In other words, the housings 3, 103 are fitted together by coupling by pushing the rack 200 in the coupling direction M1 such that the electrical terminals 5, 105 are in complete contact with each other at the engagement surface E initially.
[0067] At the same time, the shell 7 is received in the latching space 113 and the latching device 109 is received in the receiving space 31, such that the form-fit connections F1, F2 described with reference to Fig. 4C are respectively realized by the shell 7 and the connector locking device 9. In particular, the form-fit F1 prevents the abutted terminals 5, 105 from being separated, in particular from relative movement along the mating axis M. Thus, fretting due to longitudinal vibrations is not possible.
[0068] Furthermore, in this embodiment, the compressed coil spring 209 applies a coupling force F3 parallel to the mating direction M1 and the mating axis M to the housing 3 via the flange 21 or the flange portion 23a, thereby maintaining the electrical terminals 5, 105 in contact even in the event of vibration.
[0069] Advantageously, the connector assembly 100 absorbs the difference in vibrational motion between the counter electrical connector 101 mounted to the frame of the vehicle and the electrical connector 1. This is shown in Figures 6A and 6B, which are enlarged views of section C of Figure 5. In accordance with the present invention, the electrical connector 1, when mated to the counter electrical connector 101 in a mated state, vibrates at the same frequency or motion as the counter electrical connector 101 and is not affected by vibrations of the rack 200.
[0070] In practice, as described with reference to Fig. 3A, the electrical connector 1 is suspendedly mounted in the rack 200 and maintains one or more degrees of freedom even when mounted to an external device. For example, in Fig. 1, the electrical connector 1 has at least three degrees of freedom, one along the mating axis M and two perpendicular to the mating axis M, plus possibly a rotational degree of freedom.
[0071] As the rack 200 vibrates longitudinally along the mating axis M, the pin 205 and the connector locking device 9 positively and / or frictionally engage the rack 200 at the interface I and move with the rack 200. Because the diameter D3 of the bore 25a is larger than the diameter D4 of the pin 205, the pin 205 does not transmit vibrations to the shell 7 through the flange 21. The connector locking device 9 does not transmit vibrations to the shell 7 because of its sliding contact with the outwardly facing surface 17. Thus, no relative movement occurs between the terminals 5, 105, and fretting corrosion due to vibration is reduced or avoided.
[0072] As can be seen in Figures 6A and 6B, the distance J1 between the rack 200 and the flange 21 of the shell may change due to vibration, but the connector 1 remains firmly locked and coupled to the counter connector 101, since the connector locking device 9 together with the rack 200 slides between the notch 131 and the first surface portion 43 over the interface K parallel to the mating axis M. The interface K extends over a certain linear range R, which in this embodiment corresponds to the length of the first surface portion 43. Thus, the form-fit connection F1, F2 is ensured. The lance 119 remains movably blocked by the first surface portion 43, i.e., the lance 119 is blocked in a direction P perpendicular to the mating direction M, but is movable over a certain linear range R. Thus, longitudinal vibrations or relative position changes of the rack 200 with respect to the shell 7 along the mating axis M are absorbed and fretting corrosion at the terminal interface E is inhibited.
Claims
1. An electrical connector comprising a housing (3) and an electrical terminal (5), the housing (3) and the electrical terminals (5) are configured to mate with a mating housing (103) and mating electrical terminals (105) of a counter electrical connector (101) along a mating axis (M); The housing (3) includes a shell (7) at least partially surrounding the electrical terminals (5); the shell (5) includes a protrusion (19) formed on an outwardly facing surface (17) that enables a form-fit connection (F1) with a hook-like latching device (109) of the counter electrical connector (101) along the mating axis (M); The housing (3) further includes a connector locking device (9) at least partially surrounding the shell (5); the connector locking device (9) slidingly contacts the shell (5) to allow movement of the connector locking device (9) relative to the shell (5) along the mating axis (M); the connector locking device (9) is configured to prevent the form-fit connection (F1) between the latch device (109) and the protrusion (19), in particular along a direction (P) perpendicular to the mating axis (M), in a mated state in which the electrical connector (1) and the counter electrical connector (101) are mated. Electrical connector.
2. an inwardly facing surface (35) of the connector locking device (9) facing the outwardly facing surface (17) of the shell (5) forms a receiving space (31) together with the outwardly facing surface (17) of the shell (5); the receiving space (31) has an opening (39) facing the protrusion (19) of the shell (5), and the receiving space (31) is configured to at least partially receive the latch device (109) through the opening (39) in the coupled state.
2. The electrical connector of claim 1.
3. The inwardly facing surface (35) of the connector locking device (9) a first surface portion (43) parallel to the outward surface (17) of the shell (5) and a second surface portion (45) adjacent to the first surface portion (43) on the opening side of the receiving space (31), the second surface portion (45) is chamfered relative to the mating axis (M) such that the distance between the second surface portion (45) and the outwardly facing surface (17) of the shell (5) gradually increases towards the opening (39).
3. The electrical connector of claim 2.
4. A mating electrical connector comprising a mating housing (103) and a mating electrical terminal (105), the mating housing (103) and the mating electrical terminals (105) are configured to mate with the housing (3) and the electrical terminals (5) of the electrical connector (1) according to claim 1 along a mating axis (M); The mating housing (103) includes a mating shell (107) that at least partially surrounds the mating electrical terminals (105), The mating housing (103) further includes a preferably hook-shaped latching device (109), the latching device (109) extending along and spaced apart from an outwardly facing surface (117) of the mating shell (107); the latch device (109) comprises a lance (119) extending parallel to the mating axis (M) and a mating projection (121) extending from a face (123) of the lance (119) facing the outward surface (113) of the mating shell (107) towards the outward surface (113) of the mating shell (107), the mating projection (121) enabling a form-fit connection (F1) with the protrusion (19) of the shell (5) of the electrical connector (1) along the mating axis (M); the lance (119) of the latch device (109) has one tip (129a) fixed to the mating shell (107), and a second tip (129b) of the lance (119) is configured and arranged such that in a mated state, the second tip (129b) of the lance (119) is blocked by the connector locking device (9) of the electrical connector (1), in particular along a direction (P) perpendicular to the mating axis (M); Counter electrical connector.
5. The lance (119) extends perpendicularly from a flange (125) attached to a mating flange (127) of the mating shell (107).
5. The mating electrical connector of claim 4.
6. the latch device (109) further comprises a notch (131) formed in the second tip (129b) on an outwardly facing surface (133) opposite the surface (123) of the lance (119) facing the outer surface (113) of the mating shell (107); 5. The mating electrical connector of claim 4.
7. 1. A connector assembly comprising: An electrical connector (1) according to any one of claims 1 to 3, A mating electrical connector (101) according to any one of claims 4 to 6 and Equipped with The electrical connector (1) is coupled to the counter electrical connector (101); The electrical terminal (5) of the electrical connector (1) abuts against the mating electrical terminal (105) in a plane perpendicular to the mating axis (M), said projections (19) and said mating projections (121) provide a form-fit connection (F1) between said latch device (109) and said shell (5) along said mating axis (M) and prevent uncoupling, in particular against the coupling direction; the second tip (129b) of the lance (119) is blocked by the connector locking device (9) in a direction (P) perpendicular to the mating axis (M) and away from the shell (5) of the electrical connector (1); Connector assembly.
8. the lance (119) of the latch device (109) is bent towards the shell (5) of the electrical connector (1) by the connector locking device (9), particularly when combined with claim 2, by the inwardly facing surface (35) of the connector locking device (9); 8. The connector assembly of claim 7.
9. the form-fit connection (F1) between the latch device (109) and the connector locking device (9) is achieved by the engagement (F2) of the notch (131) with the second surface portion (45); A connector assembly according to claim 7 or 8 in combination with claims 3 and 6.
10. a rack (200) for mounting the connector assembly (100) to the external device, in particular a vehicle device, such that the connector assembly (100) has one or more degrees of freedom when mounted to the external device; the electrical connector (1) is disposed in an opening in the rack (200) such that the rack (200) extends partially between the flanges (21, 23a, 23b, 23c) of the shell (5) and the connector locking device (9); the rack (200) is movable relative to the shell (5) and frictionally and / or positively engages the connector locking device (9); the lance (119) remains movably blocked by the connector locking device (9) over a predetermined linear range (R) of relative position of the rack (200) with respect to the shell (5) along the mating axis (M); A connector assembly according to any one of claims 7 to 9.