Connector kit, manufacturing method for connector kit, and connection method to connector kit

Abstract

To provide a connector kit that meets a more cost-effective or more simple manner.SOLUTION: A connector kit includes: a power connector for bringing a cable core of a shielded high-voltage conductor into contact with a mating connector; a shield header (110) with a shield header contact (114), the shield header forming a shield path between a shield conductor of the shielded high-voltage conductor and a shield housing of an aggregate, the shield housing including an interface opening; and a multifunctional adapter which has an aggregate connection section (312) for the electromechanical coupling with the shield header and a shield housing and a shield header opening (320). An adapter between the aggregate connection section and the shield header opening electrically closes the shield path between the shield housing of the aggregate and the shield conductor.SELECTED DRAWING: Figure 18

Description

[Technical Field]

[0001] The present invention relates to a connector kit and a manufacturing method suitable for the connector kit, and further to a method of using such a connector kit to connect an aggregate to a shielded high voltage conductor. [Background technology]

[0002] Particularly in the vehicle industry, multiple assemblies are used that require electrical shielding. For this purpose, the assemblies are usually equipped with a shielded housing. Furthermore, the assemblies are supplied with power, particularly in the form of high voltage. Shielded high-voltage conductors can be used for this purpose. The high-voltage conductors may need to be connected to the shielded housing. Multiple assemblies require multiple adaptations, and shielding complicates the adaptation. Summary of the Invention [Problem to be solved by the invention]

[0003] The present invention is based on the object of making a connector that meets at least one of the above requirements in a better and more cost-effective or simpler way. [Means for solving the problem]

[0004] The above object is met by the objects of the independent claims. Advantageous further developments are the objects of the dependent claims.

[0005] A non-limiting exemplary embodiment simplifies providing a shield path between the shield housing of the assembly and the shield conductor of the shielded high voltage conductor.

[0006] A first aspect relates to a connector kit for connecting a shielded high-voltage conductor to an assembly. The connector kit includes a power connector for contacting a cable core of the shielded high-voltage conductor with a mating connector of the assembly in a plug-in direction. The connector kit also includes a shield header having a manufacturer-defined shield header contact, the shield header at least partially forming a shield path between the shield conductor of the shielded high-voltage conductor and a shield housing of the assembly, the shield housing including a user-defined interface opening that allows a mating connector to contact the power connector. The connector kit further comprises a multi-function adapter having a user-defined assembly connection portion for electromechanical coupling with the shield housing of the assembly and a manufacturer-defined shield header opening extending perpendicular to the plug-in direction that allows the power connector to contact a mating connector, the multi-function adapter and the shield header contact being coupled to form a unit, and the adapter portion between the user-defined assembly connection portion and the manufacturer-defined shield header opening electrically closes the shield path between the shield housing of the assembly and the shield conductor.

[0007] The multi-function adapter allows existing shielded high voltage conductors to be easily adapted to the user's shielded housing without redesign.

[0008] In particular, the shape and material of the multi-function adapter can be adapted to existing shielded high-voltage conductors independently of the customer, thus requiring only minor or no modifications to structurally complex parts.

[0009] Connector kits allow suitable solutions for a manufacturer's entire product range. They simplify shielding by providing cost-effective, modular and scalable additional components, i.e. multi-function adapters. This also allows for greater flexibility for the user regarding modifications and less impact on the manufacturer's system. In particular, they allow for larger contact surfaces, which improves contact, especially grounding.

[0010] A second aspect relates to the connector kit according to aspect 1, comprising a second multi-function adapter, the second multi-function adapter including a user-defined second assembly connection portion for electromechanical coupling with the second shield housing of the second assembly, and a manufacturer-defined second shield header opening extending perpendicular to the plug-in direction, allowing the power connector to contact a mating connector, the user-defined second assembly connection portion having a different shape than the user-defined assembly connection portion, and the manufacturer-defined second shield header opening and the manufacturer-defined shield header opening having the same shape.

[0011] The connector kit allows existing shielded high voltage conductors to be easily adapted to a user's shielded housing without the need for new design.

[0012] A third aspect relates to a connector kit according to any one of the previous aspects, wherein the adapter contact surface of the assembly connection part is in electrical contact with the shield housing in the plug-in direction, and in particular the adapter contact surface is structured, the structure perpendicular to the plug-in direction having an extension of 0.1 μm to 5 mm, and the structure in the plug-in direction having an extension of 0.1 mm to 2 mm.

[0013] The connector kit therefore allows for easy connection with the shield housing, i.e. in the plug-in direction, and this configuration allows for low contact resistance.

[0014] A fourth aspect relates to a connector kit according to any one of the preceding aspects, wherein a pass-through recess, also referred to as a pass-through hole, penetrates the assembly connection part in the plug-in direction, the pass-through recess serving to receive a fastening element for fastening the multi-function adapter to the shield housing.

[0015] The connector kit thus allows for a permanent connection with the shield housing.

[0016] A fifth aspect relates to the connector kit according to aspect 4, wherein the passage recess includes an elongated hole.

[0017] Thus, the connector kit allows for a large tolerance in the connection with the shield housing.

[0018] A sixth aspect relates to a connector kit according to any one of the preceding aspects, wherein the multi-function adapter and the shielding header are combined to form an inseparable unit, and in particular, the power connector, the shielding header, and the multi-function adapter are inseparably connected to each other.

[0019] Thus, the connector kit allows for easier handling by the user since the parts are already connected together by the manufacturer and there are fewer parts.

[0020] A seventh aspect relates to a connector kit according to any one of the preceding aspects, further comprising a connector housing, wherein the multi-function adapter and the shielding header are combined to form a unit in the connector housing, and in particular, the shielding header and the multi-function adapter are inseparably connected to each other.

[0021] Thus, the connector kit allows for easier handling by the user as the parts are already connected by the manufacturer, there are fewer parts, it provides greater stability as the parts are connected, and it provides greater safety as the insulating housing can prevent electric shock.

[0022] An eighth aspect relates to the connector kit according to aspect 7, wherein the connector housing includes an injection-molded member that is at least partially injection-molded around the multi-function adapter and the shield header.

[0023] Thus, the connector kit allows for easy manufacturing.

[0024] A ninth aspect relates to a connector kit according to any one of the preceding aspects, wherein the manufacturer-defined shielded header contacts contact the multi-function adapter at manufacturer-defined shielded header openings perpendicular to the plug-in direction.

[0025] Therefore, the connector kit allows for simple manufacturing since the shield header contacts and the shield header openings can be coupled only by a force-fit connection.

[0026] A tenth aspect relates to a connector kit according to any one of the preceding claims, further comprising a crimp connection for closing the shield path between the shielded header and the shielded conductor of the shielded high voltage conductor.

[0027] Thus, the connector kit allows for easy manufacturing.

[0028] An eleventh aspect relates to a connector kit according to any one of the preceding claims, wherein the multi-function adapter includes a plurality of manufacturer-defined shielded header openings that allow a plurality of power connectors to be contactable with a plurality of mating connectors.

[0029] Thus, the connector kit allows for connection to multiple power connectors.

[0030] A twelfth aspect relates to a method of manufacturing a connector kit for connecting a shielded high voltage conductor to an assembly, the method comprising: providing a power connector for connecting the cable core of the shielded high voltage conductor to a mating connector of the assembly in a plug-in direction; providing a shielded header having manufacturer-defined shielded header contacts, the shielded header at least partially forming a shield path between a shield conductor of the shielded high voltage conductor and a shield housing of the assembly, the shield housing including a user-defined interface opening that allows a mating connector to contact the power connector; manufacturing a multi-function adapter having a user-defined assembly connection portion for electromechanical coupling with the assembly's shield housing and a manufacturer-defined shield header opening extending perpendicular to the plug-in direction to allow the power connector to contact a mating connector; and combining the multi-function adapter and the shielded header to form a unit, such that the adapter portion between the user-defined assembly connection portion and the manufacturer-defined shielded header opening electrically closes the shielded path between the assembly's shielded housing and the shielded conductors.

[0031] The twelfth aspect has the same advantages as the first aspect. The twelfth aspect can be combined with any one of aspects 1 to 11.

[0032] For example, a thirteenth embodiment similar to the seventh embodiment relates to a method according to the twelfth embodiment, The method further includes a step of housing integration of the multi-function adapter and the shield header into a connector housing, in particular, the housing integration includes an injection molding process for manufacturing the connector housing as an injection molded member.

[0033] A fourteenth aspect relates to a connection method for electrically closing a shield path between a shield conductor of a shielded high voltage conductor and a shield housing of an assembly, the method comprising: providing a connector kit (100) according to any one of aspects 1 to 13 above, or manufactured by a method according to aspect 12 or 13 above; The adapter contact surface of the assembly connection part is electrically contacted with the shield housing in the insertion direction. Includes.

[0034] The method therefore allows for a particularly easy to implement shield connection. The fourteenth aspect has the same advantages as the first aspect. The fourteenth aspect can be combined with any one of aspects 1 to 13.

[0035] A fifteenth aspect relates to a connection method according to the fourteenth aspect similar to the fourth aspect, the method comprising: The method further includes mechanically connecting the assembly connection to the shield housing, and in particular, the mechanical connection includes: Guiding the clamping element in the insertion direction through a passage recess passing through the assembly connection part; fastening the clamping element to the clamping element receptacle of the shield housing; Further includes:

[0036] For a better understanding of the present invention, it will be described in more detail using exemplary embodiments shown in the following drawings. Identical parts are provided with identical reference numerals and component names. Furthermore, individual features or combinations of features of the different examples shown and described can themselves represent independent inventive solutions or solutions according to the present invention.

[0037] The present invention will be explained below with reference to the drawings. [Brief explanation of the drawings]

[0038] [Figure 1] 1 is a schematic diagram of the connection of the assembly to a shielded high voltage conductor using a multi-function adapter. [Figure 2] 2 is a schematic cross-sectional view of the connection of FIG. 1 according to a first example; [Figure 3] FIG. 1 is a cross-sectional view of an example of a multi-function adapter. [Figure 4] 10A and 10B are cross-sectional views of further examples of multi-function adapters. [Figure 5]2 is a schematic cross-sectional view of the connection of FIG. 1 according to a second example. [Figure 6] 10A and 10B are cross-sectional views of further examples of multi-function adapters. [Figure 7] 10A and 10B are cross-sectional views of further examples of multi-function adapters. [Figure 8] FIG. 1 is a top view of an example of a multi-function adapter. [Figure 9] FIG. 10 is a top view of a further example of a multi-function adapter. [Figure 10] FIG. 10 is a top view of a further example of a multi-function adapter. [Figure 11] FIG. 10 is a top view of a further example of a multi-function adapter. [Figure 12] FIG. 10 is a top view of a further example of a multi-function adapter. [Figure 13] FIG. 10 is a top view of a further example of a multi-function adapter. [Figure 14] 1 is a side view of a connection between an assembly and a shielded high voltage conductor using a multi-function adapter, according to an example. [Figure 15] FIG. 15 is a cross-sectional view of FIG. 14 including an assembly. [Figure 16] FIG. 15 is a further cross-sectional view of FIG. 14 including an assembly. [Figure 17] FIG. 15 is a side view of FIG. 14 according to an alternative embodiment. [Figure 18] 10A and 10B are further diagrams illustrating portions of a connector kit according to an example. [Figure 19] FIG. 1 illustrates a shield housing including an interface opening for connection to a high voltage conductor. [Figure 20] 1 is a schematic diagram of the connection between the assembly and the shielded high voltage conductor. [Figure 21] 20 is a cross-sectional view of the shield housing according to FIG. 19 including a user adapter. DETAILED DESCRIPTION OF THE INVENTION

[0039] For example, as shown in FIG. 19 , the shield housing 1200 of the assembly typically includes a user-defined interface opening 1210. The interface opening 1210 is used to connect the power connector to a mating connector. The location and shape of the interface opening 1210 are typically limited by the installation space and defined by the user. Therefore, the interface opening 1210 is typically not influenced by the connector manufacturer.

[0040] In addition to the assembly, the power supply may also be shielded, for example, by the end customer. Additionally, it may be necessary to connect the power supply's shield to the shield housing 1200. To this end, the shielded high voltage conductor may include a shield header 1110 that includes a shield header contact. The dimensions of the shield header 1110 and the shield header contacts may be specified by the connector manufacturer, and there are typically numerous manufacturer-specific catalog products.

[0041] Therefore, the user-defined interface opening shape, defined by the installation space, and the manufacturer-defined shield header contact shape are not coordinated with each other, which is unfavorable for electromechanical coupling. The mismatch in shape can, among other things, result in insufficient or no electrical contact to the shield path, insufficient shielding in the contact area, and / or unequal potentials of the shield housing and the shield header.

[0042] Therefore, as shown in FIG. 20 , the shield header 1110 must be adapted to the interface opening of the shield housing 1200. This requires adaptation of other components of the high-voltage plug connection system 1100. The high-voltage plug connection system 1100 typically includes the shield header 1110 and a power connector 1120 for contacting the cable core (not shown) of the shielded high-voltage conductor with a mating connector (not shown) of the assembly. This adaptation is costly and labor-intensive. Furthermore, the high-voltage plug connection system 1100 includes a connection, e.g., a crimp connection 1130, for closing the shield path between the shield header 1110 and the shield conductor 1142 of the shielded high-voltage conductor. This connection must also be adapted.

[0043] Alternatively, the user may provide a user adapter to accommodate the shielded header opening on the shielded header, as shown in Figure 21. Such shielded header openings on user adapters have been found to have poor shielding properties and are expensive to manufacture.

[0044] In particular, the shield housing of the assembly may be formed from a material that makes it difficult to establish a reliable contact over its service life. Furthermore, the shield header opening may have a variable shape, which may significantly affect the adaptation of the shield header contact and power connector in the header. This complicates the shape and shield adaptation and increases costs. Furthermore, there may be different requirements for the shield and connector of the assembly, which usually results in higher requirements for the connector in terms of shielding. Because the connection between the connector and the assembly is made at, if not the lowest, lower system level, the adaptation of the shield header contact and power connector is associated with high costs because it affects all higher system levels. The above problems increase the cost of connector adaptation because users use user-defined interface openings. This extremely large adaptation of connector shielding affects the entire product lineup of connector manufacturers. However, due to the large number of possible assemblies with different performance requirements, a standard for shielded headers has not yet been widely adopted.

[0045] The present invention is also based on the object of making a connector that meets at least one of the above requirements in a better and more cost-effective or simpler way.

[0046] In the following description, a kit, also referred to as a configuration kit, is understood to mean a collection of connector parts and accessories required for a particular user or operator. These kits can include different types of connectors, such as headers and power connectors manufactured specifically for use in the automotive industry. The connector kit includes multiple components, including male and female power connectors and shielded headers of different sizes and configurations, adapters, cables, protective covers, tools, and instructions for assembly or installation.

[0047] Kits allow users to obtain all the components needed for their particular requirements without the components having to be modified specifically for their application by the manufacturer.

[0048] Shielded high voltage conductors are cables specifically designed to carry high voltage currents and at the same time include measures to reduce or shield electromagnetic interference (EMI).

[0049] For example, a shielded high voltage conductor may consist of one or more insulated conductors, hereinafter referred to as the cable core, surrounded by an outer shield, hereinafter referred to as the shield conductor. The shield conductor may be formed from a metal braid, a metal foil, or other conductive material.

[0050] Shielding conductors help control electric fields and minimize the propagation of electromagnetic interference that can be generated by high voltages, thereby reducing interference with adjacent electronic devices and increasing safety.

[0051] Shielded high voltage conductors are used in a variety of applications such as power transmission, high voltage grids, high voltage testing, medical equipment, and high voltage laboratories. The specific design and construction of such conductors depends on the specific requirements of the application and the safety standards and regulations that must be followed.

[0052] In the automotive industry, high voltages can be used in various applications, particularly in electric and hybrid vehicles, as well as in certain electrical systems of conventional vehicles. The battery voltage of electric and hybrid vehicles is typically between 200 and 800 volts. This voltage allows the necessary power to be supplied to the electric motor. The high voltage of a vehicle's electric drive system can vary depending on the type and power requirements. Typical voltage values ​​are often between 400 volts and several kilovolts (kV). The high-voltage electrical system of an electric or hybrid vehicle can include voltages from 12 volts to several hundred volts to operate various components of the vehicle system, such as lighting, air conditioning, and infotainment. High voltages are also used in electric vehicle chargers and charging infrastructure to provide energy to the battery. The voltage can vary depending on the charging technology and charging power.

[0053] An aggregate is understood here to be a group of assembled units or components that perform a specific function, which may vary, for example in the automotive industry, from drive aggregates such as engines and transmissions to auxiliary aggregates such as air conditioning compressors or power steering.

[0054] Examples of assemblies are engine assemblies, transmission assemblies, air conditioning assemblies, electrical assemblies such as generators, starter motors, batteries, chargers and charging infrastructure required for the power and operation of the vehicle's electrical system, and safety assemblies such as airbags, belt tensioners, ABS systems, etc.

[0055] In general, the term aggregate refers to a group of units or components that perform a specific function and can be thought of as a higher level unit, for example an independent module within a vehicle.

[0056] In the field of electrical connectors, a power connector is a device used to connect two or more electrical cable wires together to establish an electrical connection. Power connectors ensure a reliable electrical connection between the cable core and the mating connector of the assembly, ensuring the flow of electrical current, especially in the high-voltage range.

[0057] There are different types of electrical power connectors, which can be configured differently depending on the application and system requirements. Generally, electrical connectors are plugs or sockets. The plugs include pins, and the sockets are configured to receive the pins. When the plug and socket are connected to each other, an electrical connection is established.

[0058] Alternatively, for example, clamp connectors, solder connectors, crimp connectors, and screw connectors exist that also allow for the power connections described herein.

[0059] A header is a component used in connection with a power connector, which may also be referred to as a contact tab. A shielding header is a header that further shields the power connector, i.e., is part of a shielding path around the power connector. The shielding conductor has a shielding header contact defined by the manufacturer. The shielding header may have a hollow cylindrical shape with a polygonal base region, allowing for circumferential shielding of the power connector. The polygonal base region of the shielding header may be, for example, circular or rectangular. Different shapes of the shielding header may be defined by the manufacturer.

[0060] The shielded header further includes shielded header contacts that enable connection of the shielded header with a mating connector, particularly with a shielded header opening. Here, the shielded header contacts interact with the shielded header opening, which is adapted to the geometry of the shielded header to enable electrical connection. The shielded header contacts can be defined by the connector manufacturer. For example, to enable good electrical connection between the shielded header and the mating connector, the shielded header contacts can include a series of pins, contact elements, and / or clamping elements that protrude from or are arranged on the surface. Good electrical connection of the shielded header is understood to mean, in particular, low transfer impedance and long-term connection stability.

[0061] A multi-function adapter is herein understood to be a component that provides connection options for various assemblies, thus enabling versatility and enabling compatibility of various user-specific assemblies with manufacturer-specific shielded headers, particularly shielded header contacts.

[0062] A shielded path is an electrical or electromagnetic path provided by a shielding material, allowing, for example, the dissipation and / or absorption of EMI generated by high voltages flowing through a cable core. Thus, the shield can protect sensitive signals outside and / or inside the assembly and high-voltage conductor from interference, shunting interference currents present in the shielded path to ground and / or the assembly ground. Thus, a shielded path is a path along which interference is shunted and absorbed. An example of a shielded high-voltage conductor is a coaxial cable. In a coaxial cable, the cable core, which carries the high voltage, is surrounded by an outer shielding material.

[0063] 1 shows a first example of a connector kit 100. The connector kit 100 allows for connecting a shielded high voltage conductor, including a cable core 144 and a shielded conductor 142, to an assembly.

[0064] The connector kit includes a shielded header 110, a power connector 120, and a multi-function adapter 300. The power connector 120 is shown here separate from the shielded header 110, but may be disposed within the shielded header 110. Additionally, a shielded connector may be provided between the header and a shielded high-voltage conductor. The connector kit 100 may further include a shielded high-voltage conductor. The connector kit 100 may further include a crimp connection 120.

[0065] Thus, the connector kit allows for a shield path that connects the assembly's shield housing 1200 to the multi-function adapter 300 and then to the shield header 110. The shield path can further connect the connector's shield to the crimp connection 130 and the cable shield 142.

[0066] The connector kit also enables a power path, which may include a mating connector of the assembly, such as a bus bar and power connector 120. The power path may further include a power connector, a power crimp, and a cable core 144 of the high voltage conductor of the connector.

[0067] The power connector 120 allows the cable core 144 of the shielded high voltage conductor to contact a mating connector (not shown) of the assembly in a plug-in direction S. As previously mentioned, the power connector may include a plug or socket to allow for a connection in the plug-in direction S.

[0068] The shielding header 110 includes a manufacturer-defined shielding header contact that at least partially forms a shielding path between the shielding conductor 142 of the shielded high-voltage conductor and the shielding housing of the assembly 120, and the shielding housing includes a user-defined interface opening that allows a mating connector to contact the power connector. As previously mentioned, the shielding header can have a hollow cylindrical shape, which allows for shielding of the power connection. The shielding header contact closes the shielding path between the shielding housing and the shielding conductor.

[0069] The multi-function adapter 300 includes a user-defined assembly connection portion for electromechanical coupling with the assembly shield housing 1200 and a manufacturer-defined shield header opening extending perpendicular to the plugging direction S, which allows the power connector to contact a mating connector. The multi-function adapter 300 and the shield header contact can be mated to form a unit, such that the adapter portion between the user-defined assembly connection portion and the manufacturer-defined shield header opening electrically closes the shield path between the assembly shield housing and the shield conductor 142.

[0070] As previously mentioned, the shielded header may have a hollow cylindrical shape that allows for shielding of the plug connection. The shielded header contacts may close the shield path between the shielded housing and the shielded conductors.

[0071] FIG. 2 is a cross-sectional view of a portion of a connector kit 100 according to a first example.

[0072] A power connector is not shown, and the cable core 144 according to the example of Figure 2 can be connected to a mating connector (not shown) in the shielded housing 1200 of the assembly in a plug-in direction S. Alternatively, according to an example not shown, the power connector may be located in the shielded header 110.

[0073] 2 shows that the shield housing can include a user-defined interface opening 1210 that extends at least partially in a radial direction r perpendicular to the plugging direction S. This interface opening 1210 allows the power connector to contact a mating connector in the plugging direction.

[0074] The multi-function adapter has a user-defined assembly connection 310 for electromechanical coupling with the shield housing 1200. As shown in FIG. 2, the assembly connection 310 includes, for example, an adapter contact surface 312. The assembly connection 310 enables electromechanical coupling between the multi-function adapter and the shield housing 1200.

[0075] The multi-function adapter also includes a manufacturer-defined shielded header opening 320. The shielded header opening 320 extends at least partially in a direction perpendicular to the plugging direction S, and thus here in a radial direction r. The shielded header opening 320 allows the power connector to be contactable with a mating connector.

[0076] Although the assembly connections 310 and the shield header openings 320 in FIG. 1 are the same size, this is not necessary and the assembly connections 310 may be smaller or larger than the shield header openings 320.

[0077] Manufacturer-defined shielded header contacts 112 are provided between the shielded header 110 and the multi-function adapter. The multi-function adapter and the shielded header contacts are manufactured separately. The separate components are then combined by the manufacturer to form a unit. Thus, the adapter portion 310 allows the assembly connection portion 312 to be manufactured in a user-defined manner. This simplifies the process, since the manufacturer does not need to re-adapt the shielded header 110 with the shielded header contacts 112 to a specific user, particularly regarding the shielding characteristics. Furthermore, this electrically closes the shield path between the assembly's shielded housing 1200 and the shielded conductor 144.

[0078] Next, the multi-function adapter will be described in detail with reference to Figures 2 to 4. As shown in Figure 3, the multi-function adapter can have a plate shape. Here, the plate has two flat surfaces arranged opposite to each other. The first surface can be the above-mentioned adapter contact surface 312 that connects to the shield housing 1200 of the assembly. The second, oppositely arranged surface will be referred to as the connector surface 314 below.

[0079] The multi-function adapter is provided with a shielded header opening 320. The shielded header opening 320 may be adapted by the manufacturer for a shielded header.

[0080] This multi-function adapter structure facilitates manufacturing of the multi-function adapter, for example, as a stamped and bent member. This minimizes design effort by allowing the shielding header opening 320 to be precisely adapted to fit the shielding header 110, particularly the shielding header contacts. This allows the connector kit manufacturer to control the electrical characteristics up to and including the adapter section 310.

[0081] 2, the adapter contact surface 312 of the assembly connection electrically contacts the shield housing 1200 in the plug-in direction S. This allows for a particularly efficient shield contact, since the contact surface can be easily enlarged, especially in the radial direction r.

[0082] To further increase the contact area and reduce the contact resistance, the adapter contact surface can be structured, as shown in the variant of FIG. 4. A coating can be provided, or the adapter contact surface can have a structure 313 by methods such as embossing or etching. In particular, this can be a microstructure. Such microstructuring creates irregularities that can penetrate the possibly present electrically insulating surface layer of the contacting shield contact header. This significantly reduces the electrical contact resistance at the interface with the shield contact header.

[0083] The microstructured adapter contact surface can be at least partially formed integrally with the multifunction adapter. Producing the microstructured contact area integrally with the multifunction adapter, i.e., in one piece, has the advantage of simplified manufacturing and assembly and improved electrical conductivity. The microstructured contact area may also be formed as a separate element, such as a screen sheet. This has the advantage that a different material may be selected for the microstructured contact area than for the respective sleeves.

[0084] According to an advantageous further development, the microstructured adapter contact surface is at least partly formed as an additional coating on the multifunctional adapter, which is applied together with the multifunctional adapter in one working step, but can nevertheless comprise a different material than the multifunctional adapter.

[0085] For example, the microstructured adapter contact surface may be formed at least in part by embossing, punching, and / or screen sheeting. The selection of the most appropriate embodiment depends on the type of shield housing to be contacted and the subsequent application environment.

[0086] According to an advantageous aspect of the invention, the microstructured adapter contact surface is at least partially formed by cold spray surface structuring. Cold spray is a coating process in the field of thermal spraying. Compared to conventional processes, cold spray offers certain advantages, since the spray material does not melt or dissolve during the process. This allows for a wider and more flexible range of applications than other thermal processes.

[0087] The high kinetic energy of the particles and the associated high degree of deformation when they strike the component typically allows the production of homogeneous, very dense layers with variable layer thicknesses ranging from several hundred millimeters to several centimeters. For example, the structures 313 perpendicular to the insertion direction can have an extension of 0.1 μm to 5 cm, and the structures in the insertion direction can have an extension of 0.1 mm to 5 cm.

[0088] For example, a metal layer is produced whose physical and chemical properties are almost identical to those of the starting material of the respective multifunctional adapter. A process gas, preferably nitrogen or helium, is supplied to the spray gun at a pressure of up to 50 bar and heated to a maximum temperature of 1100°C in the gun housing.

[0089] The heated, pressurized gas then expands in a convergent-divergent nozzle to ambient pressure, accelerating the process gas to supersonic velocities while simultaneously cooling it to a temperature below 100°C.

[0090] The spray powder is injected into the nozzle's convergent region by a powder feed unit, and the same type of carrier gas is accelerated in the main gas stream to particle velocities of up to 1200 m / s. The particles strike the (often untreated) component surface in a highly focused spray jet, simultaneously deforming the substrate and the particles themselves, forming a tightly adherent, dense, low-oxide layer with a defined surface roughness.

[0091] To further improve the shielding properties, an appropriate material can be selected for the multi-function adapter, for example, the multi-function adapter may include or consist of a metal, such as stainless steel.

[0092] 2, the passage recesses 316 penetrate the assembly connection in the plug-in direction. Each passage recess has a fastening element 416, such as a screw, that fastens the multi-function adapter to the shield housing. The passage recesses 316 reduce the contact resistance between the multi-function adapter 300 and the shield housing 1200.

[0093] For example, the recess can be a slot. A slot is a manufacturing term that refers to a long or narrow hole in a workpiece. This type of hole, unlike a circular hole, has an elongated, rectangular, or oval shape. This means that multi-function adapters can be manufactured with greater tolerances.

[0094] In the example of FIGS. 2-4, the shielded header contacts contact the multi-function adapter in the plug-in direction S by attaching the shielded header contacts to the connector face 316, for example, by soldering or gluing.

[0095] 5-7 show an alternative embodiment in which the shielded header contacts are contacted in the plug-in direction S. As shown in FIG. 5, the shielded header contacts 314 contact the multi-function adapter 300 perpendicular to the plug-in direction S, i.e., in the radial direction r. This allows for a force-fit connection between the multi-function adapter 300 and the shielded header contacts. In particular, the manufacturer-defined shielded header contacts 314 contact the multi-function adapter at the shielded header opening.

[0096] For this purpose, the multifunction adapter may be a thick plate, as shown in FIG. 6, for example. This increases the contact surface of the shield header opening in the plug-in direction. For example, contact surface 322 has a thickness in the plug-in direction of 2 mm to 20 mm. For example, the multifunction adapter has the same thickness. Alternatively, as shown in FIG. 7, the multifunction adapter can be provided with contact cylinders 324 extending in the plug-in direction S, thereby increasing the contact surface 322. Additionally or alternatively, the contact surface in FIG. 7 can be configured to be the same as contact surface 322 in FIG. 6, and manufactured to save material by reducing the plate thickness everywhere except for contact surface 322.

[0097] Further examples of multi-function adapters are shown in Figures 8-11. In particular, the shielding header openings of the multi-function adapters can be adapted to the shielding headers and / or shielding header contacts specified by the manufacturer. While each of the multi-function adapters shown in Figures 8-11 includes a pass-through recess, the assembly connections can instead be connected to the shielding housing, for example, by a conductive adhesive.

[0098] For example, as shown in Figures 8-10, each assembly connection can have the same shape and the same hole pattern, allowing a user to choose from a variety of manufacturer-defined shielded header contacts that all fit their shielded housing.

[0099] Additionally or alternatively, the assembly connections can be adapted to the user, as shown in Figure 11. For example, the hole pattern can be easily customized. Additionally or alternatively, the shape of the assembly connections can be adapted.

[0100] According to an example not shown, the connector kit of the above example can include a second multi-function adapter, which includes a user-defined second assembly connection portion (not shown) for electromechanical coupling with the second shield housing of the second assembly and a manufacturer-defined second shield header opening perpendicular to the plugging direction, allowing the power connector to contact the mating connector. In this case, the user-defined second assembly connection portion has a different shape from the user-defined assembly connection portion, and the manufacturer-defined second shield header opening and the manufacturer-defined shield header opening have the same shape. This allows the manufacturer to easily modify the user-defined assembly connection portion for use with manufacturer-defined shield header contacts.

[0101] 12-13 show further examples of multi-function adapters. The multi-function adapters include multiple manufacturer-defined shielded header openings, allowing multiple power connectors to interface with multiple mating connectors in the assembly. In particular, the shielded housing of the assembly may include only one interface opening, allowing the multi-function adapter to easily connect multiple power connectors.

[0102] 14-16 show a first example of a connector kit for connecting a shield housing 1200 to an interface opening 1210, as shown in FIG. 19. In this case, a shield header 110 is inserted into a manufacturer-defined shield header opening 320 of a multi-function adapter 300. In particular, FIGS. 15 and 16 show that the shield header contacts 114 contact the multi-function adapter perpendicular to the plug-in direction in the manufacturer-defined shield header opening. In other words, contact is established radially here. For example, the shield header contacts 114 are thin plates extending in a direction opposite to the plug-in direction S.

[0103] Alternatively, as shown in Figure 17, the shield header contacts 112 can be provided to extend perpendicular to the plugging direction. In other words, contact is established axially. In this case, the shield header covers the manufacturer-defined shield header opening.

[0104] Figure 18 shows a further example of a portion of a connector kit. Figure 18 shows a shielded header 110 including shielded header contacts 114. In this case, the shielded header 110 has a cylindrical shape with a rectangular base. The shielded header contacts 114 are thin plates with a U-shaped bend. The multi-function adapter includes an assembly connection portion 312 that contacts the shielded header contacts 114 in a shielded header opening 320 and contacts the assembly's shield housing (not shown).

[0105] In one example, the multi-function adapter and the shielded header are combined to form an inseparable unit. Inseparable means that the two components cannot be separated from each other without destroying the connector kit. This ensures an electrical and mechanical connection by the manufacturer. Furthermore, this means that the two components are manufactured separately and only joined together in a subsequent assembly step. For example, the two components can be joined by gluing, soldering, welding, etc.

[0106] Although the power connector is not shown in FIG. 18, the power connector can be non-detachably connected to the shielded header and the multi-function adapter.

[0107] According to the example of FIG. 7 , the connector kit can include a connector housing 500. The connector housing 500 allows the multi-function adapter and the shielding header to be coupled to form a unit. In other words, the multi-function adapter and the shielding header may not be separable without destroying the connector housing 500. This may be possible, for example, in that the connector housing 500 includes an injection-molded part. This injection-molded part may be partially molded around the multi-function adapter and the shielding header. This allows for a particularly simple, precise, and cost-effective production of the connector kit.

[0108] 18, the multi-function adapter of the connector kit includes a pass-through recess in the assembly connection portion 312. Alternatively, the pass-through recess can be provided in the connector housing to couple the connector kit to the shield housing.

[0109] Each of the connector kits described above may also include a crimp connection 130 for closing the shield path between the shielded header and the shield conductor of the shielded high voltage conductor, as shown in schematic Figure 1. This allows for a particularly cost-effective connection between the shielded header and the shield conductor 142.

[0110] Each of the aforementioned connector kits may further comprise a shielded connector, the shield of which connects the shielded header to the shield conductor and the inner conductor of which connects the power connector to the cable core.

[0111] A further example, not shown, relates to a method of manufacturing a connector kit for connecting shielded high voltage conductors to an assembly, as shown in Figures 1 to 18.

[0112] The manufacturing method includes providing a power connector for contacting a cable core of a shielded high-voltage conductor with a mating connector of the assembly in a plug-in direction. The method further includes providing a shielded header having manufacturer-defined shielded header contacts, the shielded header at least partially forming a shield path between the shielded conductor of the shielded high-voltage conductor and a shield housing of the assembly, the shield housing including a user-defined interface opening that allows a mating connector to contact the power connector. This allows the shielded header and power connector to be predefined. For example, the shielded header and power connector can be selected by a user from a manufacturer's catalog.

[0113] For customization, the manufacturing method further involves producing a multi-function adapter with a user-defined assembly connection for electromechanical coupling with the assembly's shield housing and a manufacturer-defined shield header opening extending perpendicular to the plug-in direction that allows the power connector to be contactable with a mating connector, thereby allowing the multi-function adapter to be easily manufactured for the user.

[0114] Finally, as part of the manufacturing process, the multi-function adapter and shielding header are mated to form a unit such that the adapter portion between the user-defined assembly connection and the manufacturer-defined shielding header opening electrically closes the shielding path between the assembly's shielding housing and the shielding conductor, facilitating the connection kit manufacturer's provision of the shielding path.

[0115] According to one example, the manufacturing process can include a housing integration step, where the multi-function adapter and the shield header are integrated into a connector housing, for example, the housing integration includes an injection molding process for manufacturing the connector housing as an injection molded part.

[0116] A further example, not shown, relates to a connection method for electrically closing a shield path between a shield conductor of a shielded high-voltage conductor and a shield housing of an assembly. The method includes providing a connector kit according to one of the above examples or manufactured by the above method. Finally, the method includes electrically contacting an adapter contact surface of the assembly connection part with the shield housing in a plug-in direction, thereby allowing a user to easily connect the shield housing to the shield conductor.

[0117] The connection method can further include mechanically connecting the assembly connection portion to the shield housing. For example, a connector housing can be connected to the shield housing. Additionally or alternatively, the mechanical connection can further include passing a clamping element in a plug-in direction through a pass-through recess that penetrates the assembly connection portion. By fixing the clamping element to a clamping element receptacle on the shield housing, contact resistance can be low and the contact can be made permanent. [Explanation of symbols]

[0118] 100 High Voltage Plug Connection System 110 Shielded Header 112 Shielded Header Contact 114 Shielded Header Contact 120 Power Connector 130 Crimp Connection 140 Shielded High Voltage Conductor 142 Shielded Conductor 144 Cable Core 300 Multi-function Adapter 310 Assembly connection part 312 Adapter contact surface 313 Structure 314 Connector surface 316 Passage recess 320 Shield header opening 322 Contact surface 324 Contact Cylinder 416 Clamping element 1100 High Voltage Plug Connection System 1110 Shielded Header 1120 Power Connector 1130 Crimp Connection 1142 Shielded Conductor 1200 Shielded Housing 1210 Interface opening 2230 User Adapter 2232 Shield header opening S Insertion direction r radial direction

Claims

1. A connector kit (100) for connecting a shielded high voltage conductor to an assembly, said connector kit (100) comprising: a power connector (120) for contacting the cable core (144) of the shielded high voltage conductor with a mating connector of the assembly in a plug-in direction (S); a shielded header (110) having manufacturer-defined shielded header contacts (112, 114), said shielded header (110) at least partially forming a shield path between a shield conductor (142) of said shielded high voltage conductor and a shielded housing (1200) of said assembly, said shielded housing (1200) including a user-defined interface opening (1210) that allows said mating connector to contact said power connector; a multi-function adapter (300) having a user-defined assembly connection (312) for electromechanical coupling of the assembly with the shield housing (1200) and a manufacturer-defined shield header opening (320) extending perpendicular to the plug-in direction (S) to allow the power connector to be contacted with the mating connector; Equipped with A connector kit (100) capable of combining the multi-function adapter (300) and the shield header contact (112) to form a unit such that the adapter portion (310) between the user-defined assembly connection portion (312) and the manufacturer-defined shield header opening (320) electrically closes the shield path between the shield housing (1200) of the assembly and the shield conductor (142).

2. a second multi-function adapter, the second multi-function adapter comprising: a user-defined second assembly connection for electromechanical coupling with the second shield housing of the second assembly; a manufacturer-defined second shield header opening extending perpendicular to the insertion direction (S) that allows the power connector to contact the mating connector; Including, the second user-defined assembly connection is shaped differently than the first user-defined assembly connection (310); The connector kit (100) of claim 1, wherein the manufacturer-defined second shielding header opening and the manufacturer-defined shielding header opening (320) have the same shape.

3. an adapter contact surface (312) of the assembly connection portion (310) electrically contacts the shield housing (120) in the insertion direction; 3. The connector kit (100) according to claim 1 or 2, wherein in particular the adapter contact surface (312) is microstructured.

4. 4. A connector kit (100) according to any one of claims 1 to 3, wherein a passage recess (316) penetrates the assembly connection portion (310) in the insertion direction (S), and the passage recess (316) functions to receive a fastening element (416) for fastening the multi-function adapter (300) to the shield housing (1200).

5. The connector kit (100) of claim 4, wherein the passage recess (316) comprises an elongated hole.

6. The connector kit (100) of any one of claims 1 to 5, wherein the multi-function adapter (300) and the shielding header (110) are combined to form an inseparable unit, and in particular, the power connector (120), the shielding header (110), and the multi-function adapter (300) are inseparably connected to each other.

7. 7. The connector kit (100) of claim 1, further comprising a connector housing (500), wherein the multi-function adapter (300) and the shielding header (110) are combined to form a unit in the connector housing (500), and in particular, the shielding header (110) and the multi-function adapter (300) are inseparably connected to each other.

8. 8. The connector kit (100) of claim 7, wherein the connector housing (500) comprises an injection molded member that is at least partially injection molded around the multi-function adapter (300) and the shield header (110).

9. 9. The connector kit (100) of claim 1, wherein the manufacturer-defined shielded header contacts (114) contact the multi-function adapter (300) at the manufacturer-defined shielded header openings (320) perpendicular to the insertion direction (S).

10. a crimp connection (130) for closing the shield path between the shield header (110) and the shield conductor (142) of the shielded high voltage conductor; and / or a shield connector; 10. The connector kit (100) of claim 1, wherein a shield of the shielded connector connects the shielded header (110) to the shielded conductor (142), and an inner conductor of the shielded connector connects the power connector (120) to the cable core (144).

11. 11. The connector kit (100) of claim 1, wherein the multi-function adapter (300) includes multiple manufacturer-defined shielded header openings that allow multiple power connectors to contact multiple mating connectors.

12. 1. A method of manufacturing a connector kit (100) for connecting a shielded high voltage conductor to an assembly, the method comprising: providing a power connector (120) for contacting the cable core (144) of the shielded high voltage conductor with a mating connector of the assembly in a plug-in direction (S); providing a shielded header (120) having manufacturer-defined shielded header contacts (112, 114), the shielded header (120) at least partially forming a shield path between a shielded conductor (144) of the shielded high voltage conductor and a shielded housing (1200) of the assembly, the shielded housing (1200) including a user-defined interface opening (1210) that allows the mating connector to contact the power connector; manufacturing a multi-function adapter (300) having a user-defined assembly connection (312) for electromechanical coupling of the assembly with the shield housing (1200) and a manufacturer-defined shield header opening (320) extending perpendicular to the plug-in direction (S) to allow the power connector to contact the mating connector; coupling the multi-function adapter (300) and the shield header (112) to form a unit, such that the adapter portion (310) between the user-defined assembly connection portion (312) and the manufacturer-defined shield header opening (320) electrically closes the shield path between the shield housing (1200) of the assembly and the shield conductor (144); A manufacturing method comprising:

13. 13. The manufacturing method of claim 12, further comprising a step of housing-integrating the multi-function adapter (300) and the shield header (110) into a connector housing (500), in particular, the housing-integrating step including an injection molding process for manufacturing the connector housing (500) as an injection molded part.

14. 1. A connection method for electrically closing a shield path between a shield conductor (142) of a shielded high voltage conductor and a shield housing (1200) of an assembly, said method comprising: Providing a connector kit (100) according to any one of claims 1 to 13 or manufactured by the method according to claim 12 or 13; electrically contacting the adapter contact surface (312) of the assembly connection portion (310) with the shield housing (1200) in the insertion direction (S); Including, how to connect.

15. The method further includes mechanically connecting the assembly connection portion (310) to the shield housing (1200), and in particular, the mechanical connection comprises: passing a clamping element (416) through a passage recess (316) passing through the assembly connection part (310) in the insertion direction (S); securing said fastening element (416) to a fastening element receptacle of said shield housing (1200); The connection method of claim 14 further comprising:

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