Plug-in connector device and plug-in connector

Abstract

A plug-in connector device (100) comprising a plug-in connector (1) with a contact chamber (2) and a foil body (3) having at least one contact foil (4), and a counter plug-in connector (5) with a contact element (6) inserted into the contact chamber (2) along an insertion direction (E), the contact chamber (2) having a base element (7) and a sleeve element (8), the sleeve element (8) being arranged on the base element (7) and being displaceable between a first position (P1) and a second position (P2) relative to the base element (7) along the insertion direction (E), the foil body (3) being arranged between the base element (7) and the sleeve element (8), In a first position (P1) of the sleeve element (8), the contact element (6) and / or the counter plug-in connector (5) can be displaced relative to the plug-in connector (1) in the insertion direction (E) with a force of less than 5 N, in particular without any force, and / or a radial play is formed between the at least one contact foil (4) and the contact element (6), and in a second position (P2), the foil body (3) is pressed between the sleeve element (8) and the base element (7) so that the at least one contact foil (4) is displaced radially inward at least in a predetermined section, thereby establishing an electrical contact connection with the contact element (6) at the contact section (9).

Description

[Technical Field]

[0001] The present invention relates to a plug-in connector device and a counter plug-in connector.

[0002] Prior art A plug-in connector arrangement typically comprises a plug-in connector and a counter-plug-in connector that can be mated with each other. For example, plug-in connectors for high-current applications (e.g., for currents greater than 10 A, preferably greater than 50 A, or even greater than 100 A) for electric vehicles or for automotive applications often have contact elements with spring foils, such as torus-shaped or socket-shaped foil bodies, which are connected to (e.g., shielded) lines, for example, by mechanical clamping or ultrasonic welding. In other cases, the foil bodies can be directly connected to a carrier element, such as a printed circuit board, for example, by soldering or by a press-fit contact connection. Such plug-in connectors are designed to be connected to counter-plug-in connectors that have contact elements, for example, in the form of contact pins or contact blades. The plug-in connector can be mated, for example, with the counter-plug-in connector, and the contact elements can be mated with the foil body along the insertion or plug-in direction. In the final state, the contact elements of the counter-plug-in connector (which can also be referred to as counter-contact elements) are in electrical contact with the contact elements of the plug-in connector (here, for example, the foil body). It is desirable that the spring or contact foils of the contact elements of the plug-in connector have a normal force (also referred to as contact normal force) that, in the final plug-in state, serves to ensure an electrical connection to the counter contact element over all manufacturing tolerances, even under mechanical and / or thermal loads.

[0003] However, these normal forces are usually limited because the insertion force must not exceed a specified value when connecting a plug-in connector to a counter-plug-in connector. To reduce the insertion force, lever or slider structures, for example, can be provided, which reduces the operating force during mating. However, such lever or slider structures are often complex and expensive, require a large operating space, and do not prevent damage to the surfaces that rub against each other when sliding the contact elements of the counter-plug-in connector onto the contact foil. It is certainly possible to reduce the insertion force and also reduce surface damage during the insertion process by applying a friction-reducing coating to at least one contact partner (contact element and / or counter contact element). However, this increases the cost and complexity of the manufacturing process for the corresponding contact partner and does not reliably prevent surface damage to the contact partner. This also increases the joint resistance in the area of ​​the contact location under certain circumstances.

[0004] In other applications, the contact partners (contact element and counter contact element) can be configured, for example, as a current busbar (so-called "busbar"). These contact partners can be screwed together, for example, to create a permanent contact connection. For example, in the case of a screw connection with an M4 screw, a so-called contact or normal force in the range of 2000 N to 2500 N can be achieved. Even greater normal forces can be achieved when using M5 or M6 screws. However, such a screw connection of the contact partners requires additional structural space for arranging the screws and means for tightening or loosening the screws during maintenance. Furthermore, several additional steps are required before and / or after the mating of the contact partners, which complicates the installation process. For example, the contact partners must be precisely aligned with each other to be able to tighten the screws, the screws must be arranged, an auxiliary means for tightening the screws must be arranged, the screws must be tightened, and the auxiliary means must be removed.

[0005] German Patent Application No. DE 10 2018 202 960 A1 discloses a plug-in connector for automotive and / or high-current applications, in which the contact elements are configured as foil cages. To reduce the high insertion forces (between the contact element and the counter-contact element) that occur for the operator during mating, a lever element is provided, which is actuated during the mating process when mating the plug-in connector with a counter-plug-in connector.

[0006] From DE 10 2017 213 093 A1, a plug-in contact for high-current applications is known in which the contact elements are configured as foil cages, whereby large insertion forces (between the contact element and the counter contact element) must be overcome during insertion of the counter contact element into the contact element.

[0007] German Patent Application No. DE 10 2019 131 791 A1 discloses a contact element of a plug-in connector, which is connected directly to a printed circuit board and can be contacted by inserting a pin-shaped contact element of a counter plug-in connector.

[0008] From German Utility Model No. 202008005394, a plug-in connector for high-current printed circuit boards with a foil cage is known, in which the plug-in connector can be pressed onto the printed circuit board by means of a plug socket and thereby electrically contacted.

[0009] WO 2007 / 107208 discloses a RADSOK plug-in connection consisting of a RADSOK socket (RADSOK plug-in connector) and a plug that can be plugged into the RADSOK socket (RADSOK socket), which plug-in connection forms a plug-in connector device when mated together, with the RADSOK socket and the plug being formed with locking means that allow a defined fixation of the RADSOK socket and the plug.

[0010] German Patent Application No. DE 10 2017 220 778 A1 discloses a plug-in connector having two mutually opposing foil bodies, each of which has a number of contact foils, which are designed to be contact-connected to contact elements of a counter-plug-in connector which are designed as flat contacts or contact blades.

[0011] Disclosure of the Invention The present invention is based on the recognition that if small normal (contact) forces (at one or more contact locations between a contact element and a counter contact element) exist, undesirable relative movements between the contact partners (between the contact element and the counter contact element) may occur and / or contact breakage may occur under large temperature fluctuations and / or strong vibration or oscillating loads. The present invention is also based on the recognition that in order to increase the service life of the contact connection when transmitting high currents and / or to reduce heating at the contact locations, it is advantageous to provide as large a contact surface as possible between the contact partners. Furthermore, the present invention is based on the recognition that when mating a plug-in connector with a counter plug-in connector, large insertion forces over large distances complicate the insertion process. Furthermore, the invention is based on the recognition that the application of normal forces between contact elements and counter contact elements already during the insertion process (i.e., for example, over the distance from the insertion position via intermediate insertion positions to the final insertion position or over a large portion of this distance, for example, over more than 30% of this distance) not only makes the insertion process more complicated and difficult, especially when several plug-in connectors are simultaneously mated with several counter plug-in connectors, but can also damage the surfaces of the individual contact partners. If normal forces are applied during the insertion process, wear marks or scratches can remain, for example, on the contact foils on the contact elements to be contacted. This can undesirably damage or destroy the surface coating, which can be detrimental when multiple insertions and separations are performed. In particular, such scratches or wear marks can cause the contact partners to become stuck during the insertion or separation process. In this case, high insertion forces (between the contact partners) can even undesirably reduce the number of contact partners in the plug-in connector.This is because a large number of contact partners can lead to such high insertion forces that the operating force is no longer favorable for the operator, even when using a lever or slider structure.Finally, the invention is based on the recognition that coating the contact partners can reduce the current carrying capacity and increase costs.

[0012] There may therefore be a need for a plug-in connector arrangement which allows the connection or mating of a plug-in connector with a counter plug-in connector (which may be configured, for example, as a blade strip) with as little insertion force as possible, and which, in the electrically contacted state, results in a high normal force between the contact partners and a high current-carrying capacity which provides as large a contact area as possible between the contact partners, whereby a permanent, safe, reliable and uninterrupted electrical contact connection between the plug-in connector and the counter plug-in connector is possible even in the presence of thermal stress fluctuations and / or mechanical loads, such as vibration or rocking loads, whereby only small constructional or installation space is required for the contacting process and which allows safe operation (current-carrying parts without risk of contact), whereby at least the contact partners (contact element and counter contact element) can be produced inexpensively and simply, and whereby the formation of the contact connection with the desired (contact) normal force is possible in a minimal number of steps and easily even in a complex constructional space.

[0013] Similarly, a need may arise to provide a plug-in connector having the above-mentioned characteristics.

[0014] Advantages of the invention The above needs are met by the subject matter of the invention as defined in the independent claims. Advantageous embodiments of the invention are defined in the respective dependent claims.

[0015] According to a first aspect of the present invention, a plug-in connector arrangement is proposed, in particular for high current and / or high voltage applications, in particular for automotive applications, in particular for electric vehicles (which may also include, for example, fully or partly electrically powered aircraft, ships, boats, e-bikes, motorcycles).

[0016] The plug-in connector device includes a plug-in connector with a contact chamber and a foil body having at least one contact foil. The plug-in connector further includes a counter plug-in connector with a contact element that is inserted into the contact chamber along the insertion direction. The contact chamber includes a base element and a sleeve element, and the sleeve element is disposed on the base element and is displaceable relative to the base element along the insertion direction between a first position and a second position. The foil body is disposed between the base element and the sleeve element. In the first position of the sleeve element, the contact element and / or the counter plug-in connector can be displaced along or parallel to the insertion direction relative to the contact chamber or plug-in connector with a force of less than 5 N, particularly without force. Alternatively or additionally, in the first position, radial play is formed between the at least one contact foil and the contact element. In the second position, the foil body is pressed between the sleeve element and the base element so that at least a predetermined section of the at least one contact foil is displaced radially inward, thereby electrically contacting the contact element at the contact section.

[0017] This advantageously allows the connection or mating of the plug-in connector and the counter-plug-in connector, or the contact element and the contact chamber, or the contact element and the foil body to be formed almost force-free or with very low insertion forces, with the inherent load of the contact element of the counter-plug-in connector due to the normal contact force only occurring at the end of the insertion process. Unlike conventional foil bodies, which have to expand the contact foils radially outward in the area of ​​the contact foils (the so-called "mating peak" in the insertion force) during the insertion process of the contact element of the counter-plug-in connector and have to overcome frictional forces between the contact foil and the contact element over a further distance, according to the present invention, only the increased force required to enable at least one contact foil to apply the normal contact force to the contact element is required at the end of the insertion or joining process. This advantageously facilitates the installation process and also advantageously allows for greater manufacturing tolerances, since tilting due to the insertion force is prevented and advantageously allows for further corrections of the positioning of the plug-in connector and the counter-plug-in connector even during the installation process. It is also advantageous to distribute the joining and / or plugging-in processes among various spatially separated machines or work stations on one production line. That is, in a first step, the plug-in connector and the counter-plug-in connector and / or the contact element and the foil body are, for example, simply mated or joined, with the sleeve element remaining in the first position. This occurs almost without force or with very little plugging-in force. In the achieved plugged-in state, in which the sleeve element is still in the first position, preferably at least one contact foil and the contact element already overlap (especially to a large extent).Then, in a second step (which can be carried out, for example, in another work station or by another machine or assembler), the application of the contact normal force and thus the formation of the desired electrical (and mechanical) connection can take place. This is done by applying a force (on the sleeve element) that displaces the sleeve element from the first position to the second position. In this way, pre-assembly is possible. For example, the pre-assembly process (reaching the first position) can be protected, for example mechanically, for example in the form of a primary lock, so that the pre-assembled plug-in connector arrangement can be transported to another location without any problems and without being detachable.

[0018] Furthermore, this advantageously prevents the surfaces of the contact elements and contact foils from being damaged or destroyed over a longer distance during the joining process (e.g., from the start of the overlap between the contact point of the contact foil and the contact element to the contact section of the contact element), which also makes it possible to mate and separate the plug-in connector and the counter-plug-in connector multiple times (e.g., for repairs, maintenance, etc.), which advantageously improves the durability of the plug-in connector arrangement and the components connected to it.

[0019] Furthermore, it is advantageous to increase the number of contact lamellae and / or increase the load normal force of at least one contact lamella in the final plug-in position compared to conventional plug-in connector arrangements. Alternatively or additionally, a material with a higher spring constant or a higher modulus of elasticity can be used for at least one contact lamella. This advantageously allows for an improved current carrying capacity over the service life and advantageously reduces the thermal load on the contact partners in the contact area (smaller joint resistance), thereby making the plug-in connector arrangement more robust, for example, against thermal stress fluctuations, vibrations, and / or manufacturing tolerances. According to the invention, since a large axial force only needs to be applied at the end of the plug-in process (at the (particularly small) distance of the sleeve element from the first position to the second position) to apply the radially acting contact normal force, for example, an operating element having a particularly high force transmission ratio (e.g., more than 10:1, 50:1, or 100:1) can be arranged on the plug-in connector and / or the counter-plug-in connector, despite the possibly limited operating distance. Even when the constructional space and the space for the movement of such an operating element are small, the present invention makes it possible to already transmit significant forces using simple means. Such an operating element or elements (which can be provided as an option but are not essential and therefore not essential) can be configured, for example, as a lever or slider. Such an operating element can be arranged, for example, on the plug-in connector casing or the counter-plug-in connector casing. The operating element can have, for example, a connection structure that cooperates with a complementary pin or bolt on a corresponding element (for example, when the operating element is arranged on the plug-in connector or the plug-in connector casing, the bolt or pin can be arranged on the counter-plug-in connector or the counter-plug-in connector casing).

[0020] Furthermore, the pressing of the foil bodies can advantageously increase the number of contact points between the foil bodies and the contact elements, since at least one contact foil forms multiple contact points with the contact element due to the pressing and being pressed against the contact element. This advantageously increases the current carrying capacity and reduces the joint resistance. Furthermore, the pressing of the foil bodies can advantageously increase the number of contact points between the foil bodies and the contact chambers, since the foil bodies are pressed between the base element and the sleeve element and thus pressed (especially axially). This advantageously increases the current carrying capacity, reduces the electrical joint resistance, increases the redundancy of the contact points, reduces the thermal load at the contact locations, and further improves the (radial) manufacturing tolerances and the robustness against (radial) vibration and / or rocking loads. This is because the contact formed or reinforced by pressing between the foil body and the base element or sleeve element is formed along the axial direction and thus preferably perpendicular to the contact position between the foil body and the base element or sleeve element which acts or is formed in the radial direction.

[0021] In the second position, at least one contact foil can clamp the contact element firmly, for example between itself and a wall. If several contact foils are provided, these can clamp the contact element firmly, for example between themselves.

[0022] In this case, the clamping can be formed, for example, along the radial direction. The term "firmly clamped" here means that the contact element is held securely by at least one contact foil and another clamping partner, or (if multiple contact foils are present) held between or by the contact foils, assuming that at least one contact foil applies a normal force to the contact element (i.e., the foil body is pressed in). Thus, the contact element is clamped or firmly clamped between the contact foils or between at least one contact foil and the clamping partner, viewed along the radial direction. In other words, in the second position, the contact element has an overdimension with respect to the at least one contact foil and the clamping partner (e.g., a wall or another contact foil) relative to the space defined by the at least one contact foil and the clamping partner (if only two substantially opposite contact foils are used, an overdimension can be created, for example, with respect to the spacing between the contact foils).

[0023] The sleeve element can be non-detachably positioned on the base element. For example, the base element wall can be provided with a recess into which the protrusion or locking protrusion of the sleeve element engages. As a result, the sleeve element can no longer be separated from the base element without manual intervention and is non-detachably positioned on the base element. The recess in the base element wall can have an elongated shape, for example, or can be configured so that the (locking) protrusion of the sleeve element is displaceable within the recess when moving from the first position to the second position and vice versa. Obviously, other configurations for non-detachably positioning, fixing, or holding the sleeve element on the base element are also possible. This advantageously facilitates the handling, transportation, and installation of the plug-in connector or plug-in connector device, since the plug-in connector or plug-in connector device can be handled in any spatial orientation without risk of the sleeve element falling off.

[0024] The foil can be, for example, non-detachably arranged between the base element and the sleeve element. For example, the foil can be held or fixed by at least one section to the base element and / or the sleeve element. Here, this can be, for example, a releasable (non-destructive) holding portion. For example, the foil can be clipped or pressed onto or into the holding or fastening means, or can be placed over the fastening or holding means. For example, the foil can first be placed or attached to or into the base element or the holding or fastening means of the base element, or the sleeve element can then be attached to the base element. In this way, the foil can be captured between the base element and the sleeve element. This advantageously facilitates transport and installation of the plug-in connector or plug-in connector arrangement, since the foil cannot be lost. A floating, non-detachable arrangement of the foil is also possible. That is, for example, the foil can be placed loosely between the base element and the sleeve element, but is prevented from coming out of the contact chamber by a limiting structure.

[0025] The term "force-free" in relation to the connecting or mating force means that the mating or mating of the plug-in connector with the counter-plug-in connector, or the mating or mating of the contact element with the contact chamber, or the mating or mating of the contact element with the foil body, requires almost no force or only a small mating force, at least while the sleeve element is in the first position. In particular, in the first position of the sleeve element, no engagement peaks or frictional forces between the contact partners need to be overcome to push the contact foils apart, or only small frictional forces, for example less than 10 N or less than 5 N, preferably less than 3 N, need to be overcome. In particular, in the case of power contacts for high-current or high-voltage applications, (contact) connecting or mating forces of less than 10 N, preferably less than 5 N, particularly preferably less than 3 N, can be considered to occur "force-free." Such low joining forces can be achieved, for example, if only a small radial overlap, for example an overlap of a maximum of a few micrometers, for example less than 75 μm, preferably less than 50 μm, particularly preferably less than 30 μm, is formed between the contact partners during the joining process.

[0026] The at least one contact foil can be reversibly configured, for example elastically. This means that when the sleeve element returns from the second position to the first position, the at least one contact foil returns to its starting position (i.e., is displaced radially away from the contact element). This advantageously allows the extraction process to be carried out without significant extraction forces and / or without damaging the surfaces of the contact partners. Furthermore, a new insertion or joining process can be carried out (almost) without force or with a gap between the at least one contact foil and the contact element, at least as long as the sleeve element is in the first position.

[0027] At least one contact foil can be connected to a foot element of the foil body, for example, in the rear section, where the at least one contact foil can essentially be formed free-standing in the rear section. At least one contact foil can, for example, protrude from the foot element in the direction of the counter plug-in connector, and the at least one contact foil can have a front section facing the counter plug-in connector. This front section can, for example, be free-standing, but can also be connected to the head element. The foot element and / or the head element can be formed similarly to a collar. If multiple contact foils are provided, some or all of these contact foils can be connected to the foot element in the rear section and / or to the head element in the front section of the contact foil.

[0028] The at least one contact foil can be reversibly configured, for example elastically. This means that when the sleeve element returns from the second position to the first position, the at least one contact foil returns to its starting position (i.e., is displaced radially away from the contact element). This advantageously allows the extraction process to be carried out without significant extraction forces and / or without damaging the surfaces of the contact partners. Furthermore, a new insertion or joining process can be carried out (almost) without force or with a gap between the at least one contact foil and the contact element, at least as long as the sleeve element is in the first position.

[0029] The first position of the sleeve element can be maintained until a plug-in position is reached in which a large portion of the plug-in distance between the contact element and the foil body has already been traveled (for example, more than 70%, preferably more than 90%). The plug-in distance here can, by way of example only, represent the radial overlap distance of the contact element with the foil body. The second position of the sleeve element can be reached, for example, in the final plug-in position between the plug-in connector and the counter-plug-in connector or in the final plug-in position between the contact element and the foil body.

[0030] In the first position, for example, a gap may be formed between the contact element and the at least one contact foil (during simultaneous overlap of the contact element and the foil body or contact foil). The gap may, for example, allow radial play between the contact element and the at least one contact foil. A slight radial overlap (for example, of a few micrometers) may also be provided, provided that this overlap does not result in a significant insertion or joining force.

[0031] The contact elements may have a cross-sectional diameter or extension length in the range of, for example, 2 mm to 30 mm, preferably in the range of 4 mm to 20 mm.

[0032] The individual flakes or contact flakes may have a thickness, for example, in the range of 200 μm (200 micrometers) to 3 mm, preferably in the range of 400 μm to 2 mm. For example, the flake width or width of the contact flake may be greater than the thickness of the contact flake. The flake width may be, for example, 500 μm to 6 mm, preferably 1 mm to 4 mm. The flake width may be constant, for example, along the extension direction of the contact flake. However, the flake width may increase from the contact point where the contact flake contacts the contact element towards at least one end.

[0033] The plug-in direction can be defined, for example, as the direction in which a counter plug-in connector is plugged into a plug-in connector. The plug-in direction can preferably be defined, for example, as the direction in which a contact element is displaced relative to a foil or a contact chamber in order to make contact. The plug-in direction can also be referred to, for example, as the axial direction.

[0034] The radial direction extends, for example, perpendicular to the insertion direction, and the circumferential direction surrounds the insertion direction.

[0035] The term "including" is used synonymously with the term "having," unless otherwise specified.

[0036] In one further development, the counter plug-in connector is configured with a stop structure, and when the plug-in connector is mated with the counter plug-in connector, the sleeve element is in the first position at least until it comes into mechanical contact with the stop structure, and when it is further mated to the final insertion position, the sleeve element is displaced into the second position by the mechanical contact between the sleeve element and the stop structure.

[0037] In other words, in the final mating position of the plug-in connector and the counter-plug-in connector, the sleeve element is in or has been displaced into the second position, the abutment structure exerting the necessary axial force on the sleeve element or forming a counterforce against the action of a force on the plug-in connector, so that the displacement from the first position to the second position occurs against a return force, in particular via the foil, in the direction of the first position.

[0038] This advantageously allows the mating process to be performed (almost) force-free over a large portion of the insertion distance (e.g., at least 70%, preferably at least 90%). In the butt insertion position immediately before the end of the insertion distance or the joining process, the sleeve element mechanically contacts the butt structure or the sleeve structure and butt structure are connected to each other. The remaining insertion distance from the butt insertion position to the final insertion position then presses the sleeve element into the second position by or with the butt structure as a counterforce. This advantageously provides a particularly simple mechanism for displacing the sleeve element into the second position. Separate manual manipulation of the sleeve element for displacing it into the second position is not necessary. The axial force acting between the plug-in connector and the counter-plug-in connector, for example, by the insertion movement or an operating element, such as a lever or slider, is sufficient to automatically displace the sleeve element at the end of the insertion distance and apply a contact normal force from at least one contact foil to the contact section of the contact element.

[0039] The abutment structure can be formed, for example, as a protrusion on or in the counter connector or on the counter connector housing of the counter connector. Such a protrusion can, for example, protrude axially toward the sleeve element. In another embodiment, for example, a protrusion protruding radially outward or the like can be arranged on the contact element, against which the sleeve element abuts.

[0040] In one development, a first end section of the thin film body is connected to the base element, and a second end section of the thin film body opposite the first end section is connected to the sleeve element.

[0041] This advantageously allows the foil body to be positioned easily in the contact chamber, which in turn advantageously allows a particularly simple and reliable (axial) pressing-in of the foil body to occur when the sleeve element is displaced between the first and second positions.

[0042] This also advantageously allows the foil body to be positioned in the contact chamber so that it cannot fall off.

[0043] In one development, the residual insertion distance between the plug-in connector and the counter plug-in connector, in particular from the butt insertion position where the first mechanical contact (in terms of time) between the sleeve element and the butt structure is achieved to the final insertion position (where the plug-in connector is, for example, finally established), is configured to correspond to the distance between the first position and the second position.

[0044] In other words, the plug-in connector and the counter-plug-in connector are connected with a foil (plug-in connector) or a contact element (counter-plug-in connector) without a transmission ratio.

[0045] This advantageously provides a particularly simple and robust construction, and moreover preferably makes it possible to advantageously keep the insertion distance, over which the contact partners rub against one another, very small.

[0046] In a further development, in the second position, the at least one contact foil is configured to contact the contact section each with a radial normal contact force of at least 1N, preferably at least 5N.

[0047] For example, the contact normal force of at least one contact foil, particularly of each contact foil or of several contact foils, is in the range of 5 N to 50 N or even in the range of 5 N to 200 N. This advantageously results in a particularly safe and reliable contact with a low joint resistance over the service life, even in the event of vibrations, thermal stress fluctuations, or other operating conditions. This advantageously minimizes heating at the joint between the contact partners, for example, even in the case of currents greater than 50 A or even greater than 100 A. This further advantageously reduces the construction space, weight, and material usage, particularly in the contact zone of the foil body, since a reliable contact with a high contact normal force allows for a smaller number of contact positions or contact foils. This further advantageously extends the service life of the plug-in connector device.

[0048] In one further development, the foil body is designed as a foil cage with a number of contact foils.

[0049] This advantageously provides a foil body that can be produced particularly simply and cost-effectively, and moreover preferably improves the number of contact locations and thus the current carrying capacity.

[0050] The contact lamella can be connected, for example, at its front section, to a head element in or to a head element, which can be configured, for example, in the form of a collar. Alternatively or additionally, the contact lamella can be connected, for example, at its rear section, to a leg element in or to a leg element, which can be configured, for example, in the form of a collar. This advantageously provides a particularly stable structure. The lamella cage can be designed to be self-supporting.

[0051] The lamella cage can be formed, for example, in a closed annular shape. For example, the foot element and / or the head element, which are optionally present, can be formed in a closed annular shape. In another embodiment, the lamella cage can be formed in an open annular shape, for example, with a gap between the two opposing butt edges.

[0052] For example, the respective collars or respective collar regions of the leg element and / or head element or lamina cage can be configured to be formed in a closed annular shape.

[0053] The foot region or element and / or the head region or element may have, for example, a circular or elliptical cross section in the unloaded state (i.e. before the mating plug-in connector is attached). In principle, however, polygonal cross sections of the foot element and / or head element are also possible, for example triangular, quadrangular, pentagonal, hexagonal, heptagonal, octagonal, etc. Also, cross sections with more than eight vertices are possible.

[0054] The closed annular shape can be produced by winding, for example, an originally flat stamped bending element made of sheet metal. To maintain the closed state of the leg and / or head regions, a material connection (e.g., by a welding, adhesive, or soldering process) can be provided. Alternatively, a form-fitting connection can be provided, for example, by forming at least one eyelet or a type of notch with a flat or narrow neck region at one end of the leg and / or head region, and at least one pin with a shape (fitting mechanism) complementary to the eyelet or notch at the other end of the base region. In this case, after winding the stamped bending element, at least one pin can be inserted into at least one corresponding complementary eyelet or notch, preventing further rotation and subsequent dislodging of the leg and / or head elements. A form-fitting connection advantageously allows for a particularly easy, cost-effective, and temperature-stable connection.

[0055] It will be appreciated that the open configuration of the foil cage can also be obtained by rolling stamped metal sheets together, and will be formed to be substantially shape stable (i.e., will not return to the flat metal foil shape again).

[0056] For example, the contact lamellae of the lamella cage can be configured to surround the contact space. The contact lamellae can be arranged, for example, around the contact space in the circumferential direction. In the second position, the contact element can be located within the contact space together with the contact section, where it is or can be contacted (within the contact space) by the contact lamellae.

[0057] In other words, the contact space can be formed, for example, between the radially inner contact lamellae. The contact space can be, for example, part of the interior space of the lamella cage. The contact element can be inserted into the contact space, for example, in the first position of the sleeve element and in the second position of the sleeve element. The contact space can, for example, have an overdimension (particularly along the radial direction) relative to the contact element when it is not fully inserted into the sleeve element in the first position (i.e., for example, during the insertion or joining process up to the butt insertion position). In the fully inserted state, in particular in the second position of the sleeve element, for example, the contact element can have an overdimension (particularly along the radial direction) relative to the contact space.

[0058] For example, the diameter of the foil cage can be configured to be at least 20 μm, preferably at least 50 μm, larger than the diameter of the contact element.

[0059] In one development, the first position and the second position are arranged to be spaced apart from one another along the insertion direction by a maximum of 5 mm, preferably by a maximum of 2 mm, particularly preferably by a maximum of 1 mm.

[0060] This advantageously prevents or limits surface damage to a very small distance range, since the contact partners (at least one contact foil and contact element) rub against each other, especially along a very small axial distance. This also advantageously allows for a plug-in connector device that requires very little structural space along the insertion direction. Finally, this advantageously allows for particularly high normal forces to be applied, for example, when an operating element is provided to reduce the operating force. For example, if the distance from the first position to the second position is 1 mm and the distance of an optional operating element, such as a slider element or a rotatably supported lever element, is 100 mm, a force transmission ratio of 100:1 is achieved. This allows almost the entire length of the operating element, and therefore almost the entire force transmission ratio, to be used for applying the contact normal force. It is not necessary to consume a large portion of the operating distance for the connection distance. It is also advantageous, for example, for the force transmission ratio to be very uniform along the operating distance, for example, by a substantially linear coupling characteristic with a uniform gradient at the operating element. This is because the optional actuating element is used only for the distance section from the first position to the second position, and not for the entire connecting distance between the plug-in connector and the counter plug-in connector or between the contact element and the foil body. Alternatively, with the same force transmission ratio, the actuating distance can be reduced, thereby saving structural or free space for operating the actuating element.

[0061] In one development, in the first position, the radial play between the at least one contact foil and the contact element is configured to be in the range of 5 μm (5 micrometers) to 200 μm (200 micrometers) or in the range of 20 μm to 100 μm.

[0062] This advantageously allows a large contact normal force to be generated even over a short distance between the first and second positions. Furthermore, this advantageously allows a large force transmission ratio to be achieved, since only a very small radial distance needs to be traversed or a very small gap needs to be closed for the contact connection. For example, if the axial distance between the first and second positions is 1 mm and the gap or radial play is 100 μm evenly distributed in the circumferential direction, a force transmission ratio of 10:1 can already be achieved. At the same time, such small radial play advantageously allows the insertion or joining process to be performed almost force-free, at least up to the first position. Such small play also allows for a particularly compact design of the foil and / or plug-in connector in the radial direction.

[0063] In one development, at least one contact foil is, in the first position, bent towards the contact element at least in a predetermined section.

[0064] In other words, at least one contact foil may extend obliquely from its front section and / or rear section, or from the second end section and / or first end section of the foil body, or from the head element and / or foot element of the foil body, to the contact element, or may extend obliquely relative to the contact element, or may protrude obliquely towards the contact element.

[0065] This advantageously allows the at least one contact foil to be positioned close to the contact element in the first position, i.e. the radial play or gap can be smaller than if the at least one contact foil were to extend just upwards (i.e. parallel to the insertion direction) or obliquely away from the contact element in the radial direction. Furthermore, this advantageously allows the rear section or the second end section or the head element to be positioned further away in the radial direction from the contact element, so that the contact element can pass through the rear section or the head element in an interlocked state without colliding with this rear section or the head element (and therefore a greater insertion depth can be achieved).

[0066] Furthermore, this advantageously allows the at least one contact foil to be radially displaced toward the contact element more easily and reliably, since the at least one contact foil already has a preferred radial direction toward the contact element in the absence of force. This advantageously minimizes the risk of spontaneous or unintentional damage to the at least one contact foil due to radial detachment from the contact element when the sleeve element is axially displaced from the first position toward the second position (i.e., when a force is applied to the foil body or when the foil body is axially pressed in). It should be noted that such damage due to radial detachment from the contact element can also be eliminated by other structural measures, such as intentional (e.g., thermal or mechanical) material treatment before forming the outer sleeve or the radially outwardly arranged support element or foil body. However, the curvature of at least one contact foil towards the contact element in the first position or the oblique extension of at least one contact foil towards the contact element is a particularly simple and cost-effective concept for preventing damage due to radial detachment from the contact element.

[0067] When the foil body closes a contact space into which a contact element is introduced, at least one contact foil can be configured to extend obliquely radially inward, protrude obliquely radially inward, or run obliquely radially inward in at least a predetermined section from the rear section or from the first end section or from the leg element and / or from the front section or from the first end section or from the head element.

[0068] In one development, the contact elements are circular contacts.

[0069] This advantageously allows for a particularly uniform distribution of the contact points. Furthermore, it is also advantageous that this allows for particularly simple centering of the contact elements relative to the foil body. Furthermore, it is also advantageous that the contact elements can be produced particularly simply and cost-effectively in this way. Furthermore, it is also advantageous that the contact elements can be mounted arbitrarily (for example, in or on the surface of a counter plug-in connector) since they have no preferred orientation in the circumferential direction. The contact elements can be formed, for example, as pins. They can have, for example, a circular or elliptical cross section.

[0070] Alternatively, the contact elements may be flat contacts or contact blades.

[0071] This advantageously allows for simple and cost-effective production, for example as a punched part. Furthermore, this advantageously allows for easy coding, i.e., only contact elements with the correct orientation relative to the contact chamber or foil body can be inserted into the contact chamber. This advantageously prevents incorrect installation.

[0072] In one development, a support element is arranged on the base element, and the first end section of the foil body is configured to be supported on the support element.

[0073] This advantageously allows the foil bodies to be positioned at defined positions on the base element. Furthermore, this advantageously allows functional separation to be achieved, i.e., support elements for, for example, absorbing axial forces can be formed particularly stably. This can be achieved, for example, by providing flat or specially provided support structures or surfaces for receiving or supporting foil bodies that are difficult to form directly in or on the base element. This allows the base element to be manufactured particularly simply and cost-effectively. Furthermore, the support elements advantageously simplify the manufacture of the base element. Thus, for example, the base element can be formed around a support structure that serves as a kind of internal skeleton, for example, by injection molding around the support structure or by wrapping around the support structure (e.g., by a metal foil strip that forms the base element in this case).

[0074] The support element can be formed, for example, in an annular shape, which makes it particularly easy and cost-effective to manufacture, automatically provides an air vent, and allows for easy handling during assembly. Furthermore, advantageously, the contact element can thus be engaged through the support element, which allows the contact element to be inserted deeper into the contact chamber.

[0075] Alternatively or additionally, the inner wall of the support element is configured to center the contact element in the contact chamber.

[0076] In other words, the support element can have, for example, an opening (or a connecting structure, etc.) that is slightly oversized (for example, 50 μm to 500 μm, preferably 100 μm to 350 μm, particularly preferably 180 μm to 320 μm) with respect to the contact element, or the contact element or opening can have a slightly undersized (for example, less than 50 μm, preferably less than 20 μm). When inserting the contact element, the contact element can be centered by the support element (for example, by means of the opening, connecting structure, etc.) in the contact chamber or in the base element as part of the contact chamber, in particular at the free end of the contact element.

[0077] This advantageously prevents the contact element from tipping over when inserted into the contact chamber, and further advantageously ensures that the contact element is particularly well protected over its lifetime against displacements, particularly in the radial direction, in the contact chamber, for example in the event of temperature changes, vibrations, etc., so that uninterrupted contact between the contact element and the foil body or at least one contact foil is always guaranteed.

[0078] In one development, the sleeve element has an inwardly directed (particularly facing the contact element) protrusion in the forward sleeve element section facing the opposing plug-in connector, in particular in its forward sleeve element free end, and the foil body is configured to be supported on the protrusion in its second end section.

[0079] This advantageously positions the foil in a defined position within the sleeve element, thereby providing a clearly defined impact when moving from the first position to the second position. The protrusion can also advantageously facilitate or cause the foil to be securely positioned in the contact chamber (other means for causing the foil to be securely positioned in the contact chamber are also conceivable). The protrusion can simply have, for example, a flat or specially provided support structure or surface for receiving or supporting the foil, which advantageously allows for easy installation of the foil in the contact chamber.

[0080] The protrusions may have a length, for example, of at least 500 μm, preferably at least 1 mm, particularly preferably at least 2 mm, along the axial direction, thereby achieving stable support of the lamella.

[0081] Alternatively or additionally, an inner protrusion wall of the protrusion is configured to center the contact element within the contact chamber.

[0082] This advantageously ensures that the contact element is accommodated in the correct (especially radial) position within the contact chamber or within the sleeve element as part of the contact chamber during the insertion process, or is inserted into the correct radial position within the contact chamber or within the sleeve element. This advantageously prevents damage to the at least one contact foil, for example, due to tilted or oblique insertion of the contact element. It also advantageously ensures that the at least one contact foil applies a precisely defined contact force to the contact element upon completion of the insertion process. Finally, this advantageously ensures a durable, safe, and reliable contact over the entire service life, even in the event of mechanical loads (e.g., thermal stress fluctuations, vibrations) or manufacturing tolerances.

[0083] The protrusion may have or form, for example, an opening (or a connecting structure, etc.), which may have, for example, a slight overdimension with respect to the contact element (for example, 50 μm to 500 μm, preferably 100 μm to 350 μm, particularly preferably 180 μm to 320 μm), or may have the same size as the contact element, or may have a slight underdimension (for example, less than 50 μm, preferably less than 20 μm).

[0084] In one development, the base element is configured so that it is made to a large extent from metal or plastic or consists of metal or plastic.

[0085] The use of a metal as the material for the base element advantageously allows the foil body to be particularly easily connected to, for example, an electrical line without the need to directly bond the foil body to the electrical line. Metals that can be considered include, for example, copper or copper alloys or iron, although other metals, such as silver or silver alloys, are also possible.

[0086] The use of plastic for the base element advantageously allows for particularly low-cost and flexible production of the base element, for example by injection molding. While only polyamide (PA) or polybutylene terephthalate (PBT) are considered as plastics, other plastics are not excluded. The plastic can be used with or without a glass fiber blend.

[0087] Alternatively or additionally, the sleeve element is configured so that it is formed to a large extent from metal or plastic or consists of metal or plastic.

[0088] The use of a metal as the material for the sleeve element advantageously allows for a particularly good electrical connection of the foil body to the electrical line (increased potential current paths) without the foil body having to be directly connected to the electrical line. Metals that can be considered include, for example, copper or copper alloys or iron, although other metals, such as silver or silver alloys, are also possible.

[0089] The use of plastic for the sleeve element advantageously allows for particularly low-cost and flexible production of the sleeve element, for example by injection molding. Only polyamide (PA) or polybutylene terephthalate (PBT) is considered as plastic, but other plastics are not excluded. The plastic can be used with or without a glass fiber blend.

[0090] In one development, the base element is electrically connected to the electrical line and the foil body is configured to be electrically connected to the base element.

[0091] This advantageously provides for a particularly simple and robust construction of the plug-in connector or the current-carrying parts of the plug-in connector. Furthermore, this advantageously provides for particularly short currents that result in only low joint resistance between different components or materials. At the same time, this advantageously allows the foil element to be attached to or within the plug-in connector separately from the electrical lines (the electrical lines are not mechanically fastened or fixed to the foil element). This advantageously allows for easy repair or replacement of the foil element in the event of damage. This advantageously improves the durability of the plug-in connector.

[0092] According to a second aspect of the invention, a plug-in connector, in particular for high-current and / or high-voltage applications, is proposed for plug-in connection with a counter plug-in connector provided with contact elements.

[0093] The plug-in connector has a contact chamber and a foil body with at least one contact foil, the contact chamber having a base element and a sleeve element, the sleeve element being arranged on the base element and displaceable relative to the base element along the insertion direction between a first position and a second position. The foil body is arranged between the base element and the sleeve element. In the first position of the sleeve element, the contact element and / or the counter plug-in connector can be displaced relative to the contact chamber or the plug-in connector along the insertion direction with a force of less than 5 N, particularly without force. Alternatively or additionally, in the first position of the sleeve element, a radial play is formed between the at least one contact foil and the contact element. In the second position, the at least one contact foil is displaced radially inward at least in a predetermined section, thereby forcing the foil body between the sleeve element and the base element so that the plugged contact element is electrically contacted at the contact section.

[0094] The plug-in connector is particularly configured so that displacement to the second position can be caused by abutting the sleeve element against the abutment structure of the opposing plug-in connector when mating it with the opposing plug-in connector to the final insertion position.

[0095] This advantageously provides a plug-in connector with the same advantages as the plug-in connector arrangement. In particular, it allows for (almost) force-free insertion or mating of the plug-in connector with the counter-plug-in connector or of the contact elements with the contact chambers over a large portion of the insertion distance. This further advantageously protects the surfaces of the contact partners against scratches or damage during the mating process (and also during separation from one another). The current carrying capacity is advantageously improved when the same materials are used. Further advantages have been mentioned above in connection with the plug-in connector arrangement.

[0096] The sleeve element can be arranged, for example, non-detachably, on the base element.

[0097] The foil can be arranged, for example, non-detachably between the base element and the sleeve element.

[0098] drawing Further features and advantages of the present invention will become apparent to those skilled in the art from the following description of exemplary embodiments, which are not designed to be limiting of the invention, made with reference to the accompanying drawings, in which: [Brief explanation of the drawings]

[0099] [Figure 1a] 1 shows a schematic cross-sectional view of a plug-in connector arrangement with a plug-in connector in an intermediate plug-in position and a sleeve element of the plug-in connector in a first position; [Figure 1b] 1 shows a schematic cross-sectional view of a plug-in connector arrangement with a plug-in connector in a butt insertion position and a sleeve element in a first position; [Figure 1c] 2 is a schematic cross-sectional view of a plug-in connector arrangement with a plug-in connector in a final plug-in position and a sleeve element in a second position; [Figure 2a] 1 is a schematic perspective view of a foil body of a plug-in connector in the form of a foil cage; [Figure 2b] 2b is a plan view of a stamped metal sheet as a starting state for the foil body shown in FIG. 2a;

[0100] 1a to 1c show schematic cross-sectional views of a plug-in connector arrangement 100 with a plug-in connector 1 and a counter plug-in connector 5 in various plug-in positions with the plug-in connector 1. In the following, Figures 1a to 1c will be explained together. The plug-in connector arrangement 100 can be a plug-in connector arrangement 100 for high current and / or high voltage applications, in particular for automotive applications, and in particular for electric vehicles (which can also include, for example, fully or partly electrically driven aircraft, ships, boats, e-bikes and motorcycles).

[0101] For the sake of clarity, the plug-in connector 1 is shown here without a plug-in connector casing and without actuating elements, such as slider or lever elements. The counter plug-in connector 5 has a counter plug-in connector casing 21, which is shown here only diagrammatically, for example without a plug-in collar, not shown, with which the plug-in connector casing can be mechanically coupled. The elements of the corresponding plug-in connector casing and the counter plug-in connector casing, as well as any actuating elements and operating structures (e.g., couplings on the actuating elements and pins which engage in couplings on the counter plug-in connector casing) arranged on the counter plug-in connector casing are well known to those skilled in the art; reference is also made to the above-mentioned prior art.

[0102] The plug-in process between the plug-in connector 1 and the counter plug-in connector 5 can be divided in the exemplary embodiment shown at least into the plug-in positions described below.

[0103] In the pre-plugged position, the plug-in connector 1 and the counter plug-in connector 5 are not yet superimposed or overlapped on one another, but may already be aligned with one another due to the specific coupling process.

[0104] In the intermediate plug-in position ZS, the plug-in process has already begun and the plug-in connector 1 and the counter plug-in connector 5 already overlap, but the plug-in process is not yet complete.

[0105] In the butt insertion position AS (possible in this embodiment), the sleeve element 8 of the plug-in connector 1, which will be described further below, and the here exemplarily provided butt structure 10 of the counter plug-in connector 5 are in mechanical contact with each other or are in contact with each other, in particular the sleeve element 8 and the butt structure 10 only come into contact with each other during the mating process.

[0106] In the final plug-in position ES, the plug-in connector 1 and the counter plug-in connector 5 are finally connected to one another (in particular mechanically and electrically). The plug-in process is finished. The plug-in connector arrangement 100 is ready for operation.

[0107] The insertion distance or joining distance can be defined, for example, as the distance traveled by the plug-in connector 1 relative to the counter plug-in connector 5 (or the contact elements 6 of the counter plug-in connector 5 relative to the foil body 3 of the plug-in connector 1) from the time of the first overlap to the final insertion position ES.

[0108] In FIG. 1a, the exemplary plug-in connector 1 of the exemplary plug-in connector arrangement 100 is shown in an intermediate plug-in position ZS before the abutment plug-in position AS is reached.

[0109] In FIG. 1b the same plug-in connector is shown in the butt plug-in position AS.

[0110] In FIG. 1c the same plug-in connector is shown in the final plug-in position ES.

[0111] The plug-in connector arrangement 100 comprises a plug-in connector 1 with a contact chamber 2 and a foil body 3, which has at least one contact foil 4 (two opposite contact foils 4 are visible in the cross section shown). The plug-in connector arrangement 100 further comprises a counter plug-in connector 5, which has a contact element 6 that is inserted into the contact chamber 2 along the insertion direction E. The contact element 6 protrudes parallel to the insertion direction E from a counter plug-in connector housing 21 towards the plug-in connector 1. The contact element 6 has a free contact element end 22. The contact element 6 can, for example, consist largely of a material with good electrical conductivity, such as metal, for example copper or a copper alloy. A contact protection 23 is arranged on the contact element free end 22, here by way of example. The contact protection 23 can, for example, be made of an electrically insulating material, such as plastic. The contact protection portion 23 or the free end 22 of the contact element here illustratively has a (particularly annular) inclined portion (here having a conical cross section), which allows for easy introduction of the contact element 6 into the contact chamber 2 without tilting.

[0112] The plug-in direction E can also be referred to as the axial direction. The radial direction R extends transversely or perpendicularly to the plug-in direction E, while the circumferential direction U surrounds the plug-in direction E. The plug-in direction E can also be determined by the plug-in direction between the plug-in connector 1 and the counter-plug-in connector 5. The contact chamber 2 has a base element 7 and a sleeve element 8, which here is, by way of example, non-detachably arranged on the base element 7. The sleeve element 8 is displaceable along the plug-in direction E relative to the base element 7 between a first position P1 and a second position P2 (see FIG. 1c).

[0113] The lamina 3 is arranged (here, exemplarily axially) between the base element 7 and the sleeve element 8, here exemplarily in a non-detachable manner. Here, exemplarily, a first end section 11 (rear section) of the lamina 3 is connected to the base element 7. Merely by way of example, here, a second end section 12 (front section) of the lamina 3 opposite the first end section 11 is also connected to the sleeve element 8.

[0114] In the embodiment shown here merely as an example, at least one contact foil 4 (in this case, two visible contact foils 4) is curved towards the contact element 6 in at least a predetermined section at the first position P1.

[0115] In the first position P1 of the sleeve element 8 shown in FIGS. 1a and 1b, the contact element 6 and / or the counter-plug-in connector 5 can be displaced relative to the contact chamber 2 or relative to the foil body 3 (contact element 6) and / or relative to the plug-in connector 1 (counter-plug-in connector 5) in the insertion direction E with a force of less than 5 N, in particular without any force. At the same time, a radial play is exemplarily formed between the at least one contact foil 4 and the contact element 6. The radial play or first distance D1 between the at least one contact foil 4 and the contact element 6 is exemplarily in the range of 5 μm to 200 μm or in the range of 20 μm to 100 μm. This is exemplarily caused by a gap 25. The (radial) extension of the gap 25 is exemplarily given by the first distance D1.

[0116] Displacement without force or with a force of less than 5 N relates in this case in particular to the forces required to overcome frictional forces, meshing forces, etc. Overcoming gravity, for example in the assembly of the upper head, is not taken into account here.

[0117] In the second position P2 (see Figure 1c), at least one contact foil 4 is displaced radially inward in a certain section, thereby electrically contacting the contact element 6 in one contact section 9, and the foil body 3 is pressed between the sleeve element 8 and the base element 7 so that the contact element 6 is firmly clamped.

[0118] This advantageously ensures that only small or (almost) no insertion force is required over a large portion of the insertion or joining distance, and that the surfaces of the contact partners (contact foil 4 and contact element 6) do not rub against each other or rub against each other only with very little force. The (large) contact normal force required for current transmission is then only applied at the end of the insertion or joining distance by displacing the sleeve element into the second position P2 (see FIG. 1c).

[0119] For example, the first position P1 and the second position P2 can be configured to be spaced apart from one another along the plug-in direction E by a maximum of 5 mm, preferably by a maximum of 2 mm, and particularly preferably by a maximum of 1 mm. This advantageously enables a very high force transmission ratio when the operating element is provided on the plug-in connector 1 and / or the counter-plug-in connector 5. Furthermore, this keeps the distance over which the contact partners can rub against one another very short. The axial distance between the first position P1 and the second position P2 can be referred to as the second distance D2.

[0120] The foil body 3 can be formed, for example, as a foil cage 13 with a plurality of contact foils 4. The foil cage 13 can be formed, in particular, in a closed annular shape (see FIG. 2a), although open foil cages in which two abutting edges are separated from each other by a small gap are also conceivable. In this case, the contact foils 4 can be connected within or to a first end section 11 of the foil body 3. The first end section 11 can be formed, for example, as a foot element and, for example, as a type of collar. The contact foils 4 can be connected, for example, within or to a second end section 12 of the foil body 3. The second end section 12 can be formed, for example, as a head element and, for example, as a type of collar.

[0121] Such an embodiment as a foil cage 13 can be particularly advantageous if the contact elements 6 are configured as round or oval contacts or pins.

[0122] In principle, the foil body 3 can be configured to contact a contact element 6 configured as a flat contact or contact blade. In this case, the foil body can have, for example, one or more contact foils 4 arranged substantially in one plane (i.e., arranged to surround a substantially circular cross-section, unlike the foil cage illustrated in FIGS. 2a and 2b described below). For contacting a contact element 6 configured as a flat contact (e.g., a contact blade with a rectangular cross-section), the plug-in connector 1 can have, for example, a separate foil body 3 for each side of the contact element 6 to be contacted, e.g., two foil bodies 3 facing each other. However, it is also possible to provide a single foil body 3 with two elements, each with at least one contact foil 4, bent, for example, by approximately 180° relative to one another.

[0123] Here, for example, a support element 14, which is preferably annularly shaped, is arranged on the base element 7, and the first end section 11 or the rear section of the foil body 3 is supported on the support element 14. At the same time, for example, an inner wall 15 of the support element 14 is configured to center the contact element 6 in the contact chamber 2 (see FIG. 1c). For this purpose, the support element 14 is configured as a kind of ring element, and the opening in the support element 14 is, for example, slightly oversized relative to the diameter of the contact element 6, for example, by 5 μm to 500 μm, preferably 100 μm to 400 μm, particularly preferably 180 μm to 320 μm. It is also possible for the opening 33 to not be oversized relative to the contact element 6, so that the contact element 6 has to be pressed into the opening 33 with little force. To facilitate the introduction of the contact element 6 into the opening 33, the support element 14 is, for example, provided with a lead-in ramp 24 in the area of ​​the opening 33.

[0124] The support element 14 may also advantageously facilitate the manufacture of the base element 7. For example, the base element 7 may be wrapped around the support element 14 or may be injection molded around the support element 14.

[0125] The base element 7 has a base element wall 26, a front base element section 27 facing the sleeve element 8, and a rear base element section 35 opposite the front base element section 27. The base element 7 can be hollow.

[0126] Here, by way of example, the base element 7 is electrically connected to the electrical line 20, and the foil body 3 is electrically connected to the base element 7. The electrical connection between the foil body 3 and the base element 7 here extends, in particular in the radial direction R, from the first end section 11 of the foil body 3 to the base element wall 26. In this case, the first end section 11 can be formed with at least one contact point or annular contact point zone or contact ring (not shown here for clarity) that is oriented radially outward and is embossed or curved. By means of such a structure (contact point, contact zone, etc.), a particularly well-defined contact connection in the radial direction R between the foil body 3 and the base element 7 can be achieved.

[0127] The sleeve element 8 has a front sleeve element section 16 with a front sleeve element free end 17 facing the counter plug-in connector 5 and a rear sleeve element section 34 facing the base element 7 .

[0128] For the non-detachable and simultaneously axially displaceable arrangement, connection, or mounting of the sleeve element 8 on the base element 7, a recess 28 is provided in the base element wall 26, exemplarily in the forward base element section 27, into which a locking protrusion 29 of the sleeve element 8, directed radially inward, engages. The recess 28 is closed at its forward end (facing the sleeve element 8), preventing the locking protrusion 29 from slipping off. The sleeve element 8 can be displaced in the recess 28 by means of its locking protrusion 29 between a first position P1 (see FIGS. 1a and 1b) and a second position P2 (see FIG. 1c). The recess 28 can, for example, form a limit for the relative axial displacement between the sleeve element 8 and the base element 7. However, other limiting structures for the axial displacement are also conceivable. For example, an undercut 31 is provided in the sleeve element wall 30 of the sleeve element 8 as an alternative or additional limiting structure. The undercut 31 cooperates with or is connected to a front base element free end 39 in a second position P2 (see FIG. 1c) of the sleeve element 8. The front base element free end 39 rests on the undercut 31 in the second position P2, thereby preventing further displacement of the sleeve element 8 beyond the second position P2 in the direction of the base element 7. This can, for example, protect the at least one contact foil 4 from overload or excessive pressure that could lead to plastic deformation. The stop formed in this way can, for example, ensure that the at least one contact foil 4 always remains elastically reversible.

[0129] The sleeve element 8 has, in a front sleeve element section 16 facing the counter plug-in connector 5, in particular at its front sleeve element free end 17, an inwardly directed protrusion 18 on which the foil body 3 is supported at its second end section 12. In the exemplary embodiment shown here, the protrusion inner walls 19 of the protrusions 18 are also configured for centering the contact element 6 in the contact chamber 2. For this purpose, the opening between the protrusion inner walls 19 can have an overdimension compared to the diameter of the contact element 6, for example, of 5 μm to 500 μm, preferably 100 μm to 400 μm, particularly preferably 180 μm to 320 μm.

[0130] Therefore, in the embodiment shown here, the contact element 6 is centered both by the protrusion 18 and by the support element 14, which provides particularly good protection against mechanical or thermal influences in the second position P2 or in the final insertion position ES (see Figure 1c).

[0131] In the illustrated embodiment, the base element 7 is formed to a large extent from or consists of metal, whereas in other embodiments the base element 7 may be formed to a large extent from or consist of plastic.

[0132] In the illustrated embodiment, the sleeve element 8 is formed to a large extent from or consists of metal, whereas in other embodiments the sleeve element 8 may be formed to a large extent from or consist of plastic.

[0133] The counter plug-in connector 5 has (here, exemplarily in the counter plug-in connector casing 21) a butt structure 10 (which may, for example, be arranged on the contact element 6 or, for example, protrude radially from the contact element 6). When the plug-in connector 1 is mated with the counter plug-in connector 5, the sleeve element 8 is in a first position P1 (see Figures 1a and 1b) at least until it comes into mechanical contact or coupling with the butt structure 10 (butt plug-in position AS). When mated further to the final plug-in position ES, the sleeve element 8 is displaced into a second position P2 by the mechanical contact or coupling between it and the butt structure 10 (see Figure 1c).

[0134] The abutment structure 10 is here formed, for example, as a projection, for example as an annular projection formed in the form of a ring, which here projects parallel to the plug-in direction from the counter plug-in connector casing 21 towards the plug-in connector. During the plug-in process, the sleeve element 8 abuts with its front sleeve element free end 17 against the abutment structure 10 formed as a projection.

[0135] The remaining insertion distance of the plug-in connector 1 and the counter plug-in connector 5 or of the contact element 6 and the foil body 3 from the butt insertion position AS (at this position, in particular the first mechanical contact is achieved between the sleeve element 8 and the butt structure 10) to the final insertion position ES corresponds here, by way of example, to the distance between the first position P1 and the second position P2.

[0136] In the second position P2, at least one contact foil 4 each contacts the contact section 9 with a contact normal force in the radial direction R of at least 1 N, preferably at least 5 N. In the second position P2, the combined contact normal force of all contact foils 4 on the contact section 9 can be configured to be at least 200 N overall, preferably at least 500 N, particularly preferably at least 1000 N.

[0137] FIG. 1b shows the same plug-in connector 1 as in FIG. 1a in the butt insertion position AS. The free end 17 of the front sleeve element is connected to or is in mechanical contact with the butt structure 10. Insertion is possible (almost) without force up to this butt insertion position AS, where the contact element 6 is already substantially inserted into the contact chamber 2. Furthermore, a radial play between the contact foil 4 and the contact element 6 is visible (see also the gap 25 with the first distance D1). By applying an axial force (e.g., parallel to the insertion direction E) to the plug-in connector 1 (or, for example, to the base element 7), the plug-in connector 1 can be moved to the final insertion position ES, which is only slightly further away (this distance corresponds to the second distance D2, i.e., the distance between the first position P1 and the second position P2). This force can be applied, for example, without a force transmission element or by using a force transmission element, for example in the form of a lever or slider element, such as an operating element (not shown).

[0138] 1a and 1b in the final plugged-in position ES, where the plug-in connector arrangement 100 is protected against self-opening by a locking element 32, shown here only diagrammatically and formed, for example, in the form of a clamp. The locking element 32 can be formed, for example, by a secondary locking slider, a catch element, a shield for the operating element, etc. Plug-in connector arrangements 100 that do not require such a locking element 32 are also conceivable.

[0139] In the final insertion position ES, the sleeve element 8 is in the second position P2, and the foil body 3 is pushed in along the axial direction.

[0140] The contact lamellas 4 are displaced radially inward in certain sections (here, in the central section (contact section 36) already bent in the first position P1) and electrically contact the contact element 6 in the contact section 9. The contact lamellas 4 here, by way of example, firmly clamp the contact element 6 between them. The gap 25 in FIGS. 1a and 1b is closed in the final plug-in position ES. The locking projection 29 is displaced in FIG. 1c to the upper end of the recess 28 in the base element wall 26. With its base element free end 39, the front base element section 27 rests on or is connected to an undercut 31 in the sleeve element wall 30, which here, by way of example, is formed on the inside of the sleeve element wall 30.

[0141] The embodiment shown here allows the (effective) insertion force to be applied only along a very small distance (here, the residual insertion distance corresponds to the second distance D2), without damaging the surfaces of the contact partners. Furthermore, the application of the contact normal force and the displacement of the sleeve element 8 from the first position P1 to the second position P2 can be performed in a single step, i.e., the insertion process is simply performed continuously during insertion, and the displacement of the sleeve element 8 occurs automatically by abutting against the abutment structure 10. This eliminates further, for example, manual, intervention in embodiments where the sleeve element 8 does not abut against an abutment structure or the like in the final insertion position ES and is therefore displaced into the second position independently of the first position P1, whereby a contact normal force is applied or a screw connection or the like must be formed.

[0142] In FIG. 2a, a schematic perspective view of a foil body 3 of the plug-in connector 1 is shown.

[0143] 2a shows a foil body 3 in the form of a foil cage 13, in which a plurality of contact foils 4 extend from a second end section 12 (head element) first obliquely inwardly and upwardly (radially inclined towards the contact elements 6, not shown here) and then obliquely outwardly and upwardly, where the contact foils 4 are connected to a first end section 11 (foot element) of the foil body 3. The contact foils 4 are curved (with respect to the first end section 11 and the second end section 12), in this example radially inwardly.

[0144] In other words, the contact foils 4 extend obliquely from the first end section 11 and the second end section 12 towards the contact element 11 (not shown here) in at least certain sections.

[0145] 2b shows a plan view of a stamped metal sheet as the starting state for the foil body 3 in the form of a foil cage 13 shown in FIG. 2a. The stamped metal sheet is thus still a two-dimensional precursor of the foil cage 13.

[0146] In Figure 2b, the second end section 12 of the foil body 3 and the contact foils 4 protruding upward from this second end section 12 can be seen on the bottom side. The first end section 11 of the foil body 3, to which the contact foils 4 are connected, is arranged on the top side. Two, for example, circular pins 37 can be seen on the left side of the first end section 11 and the second end section 12 in Figure 2b, which are connected to the first end section 11 or the second end section 12 by neck regions with a small diameter. Two complementary coupling recesses 38 (also with neck regions) for the pins 37 can be seen on the right side of the first end section 11 and the second end section 12 in Figure 2b. To form the foil cage 13, for example, a two-dimensional punching die can first be pressed or embossed to produce the desired extension of the contact foil 4 (e.g., a central section curving radially inward, which may also be referred to as a contact region or contact section 36). The foil cage 13 can then be formed by a winding process, with the pins 37 clipped or introduced into the coupling recesses 38, and the foil cage 13 is held shape-stable by the resulting form connection with the first end section 11 or the second end section 12, respectively (additionally, for example, further press-forming can be performed). In another embodiment, the first end section 11 and / or the second end section 12 can also be connected by a material connection (e.g., soldering, welding, adhesive bonding, etc.). In yet another embodiment, the first end section 11 and / or the second end section 12 can be formed by simple wrapping and / or, for example, embossing, so that the foil cage 13 is formed in a closed state, for example in an annular shape, so as to retain a set shape on its own, or in a nearly closed state with a small gap between the ends formed as butted edges (the left and right ends of the stamped metal sheet in Figure 2b).

Claims

1. A plug-in connector arrangement, in particular a plug-in connector arrangement for high current and / or high voltage applications, said plug-in connector arrangement (100) comprising: a plug-in connector (1) comprising a contact chamber (2) and a foil body (3) having at least one contact foil (4); a counter plug-in connector (5) with contact elements (6) that are inserted into the contact chambers (2) along a plug-in direction (E); It has The contact chamber (2) comprises a base element (7) and a sleeve element (8), the sleeve element (8) is arranged in particular non-detachably on the base element (7) and is displaceable relative to the base element (7) along the insertion direction (E) between a first position (P1) and a second position (P2), The foil (3) is arranged between the base element (7) and the sleeve element (8), in particular so as not to be detachable, In the first position (P1) of the sleeve element (8), the contact element (6) and / or the counter plug-in connector (5) are displaceable relative to the plug-in connector (1) along the plug-in direction (E) with a force of less than 5 N, in particular without any force; and / or A radial play is formed between the at least one contact foil (4) and the contact element (6), In the second position (P2), the at least one contact foil (4) is displaced radially inward in at least a predetermined section, so that it is electrically contact-connected to the contact element (6) in the contact section (9), and in particular the foil body (3) is pressed between the sleeve element (8) and the base element (7) so that the contact element (6) is firmly clamped. Plug-in connector device.

2. The opposing plug-in connector (5) has a butting structure (10), When the plug-in connector (1) and the counter plug-in connector (5) are mated, the sleeve element (8) in said first position (P1) at least until it comes into mechanical contact with said abutment structure (10); Upon further insertion into the final insertion position (ES), the sleeve element (8) is displaced into the second position (P2) by mechanical contact between the sleeve element (8) and the abutment structure (10).

2. The plug-in connector device according to claim 1.

3. a first end section (11) of the foil body (3) is connected to the base element (7); a second end section (12) of the foil body (3) opposite the first end section (11) is connected to the sleeve element (8); 3. The plug-in connector device according to claim 1 or 2.

4. the remaining insertion distance between the plug-in connector (1) and the counter plug-in connector (5) from the butt insertion position (AS) where mechanical contact between the sleeve element (8) and the butt structure (10) is achieved to the final insertion position (ES) corresponds to the distance between the first position (P1) and the second position (P2); 4. A plug-in connector arrangement according to claim 1.

5. 5. The plug-in connector arrangement according to claim 4, wherein in the second position (P2), the at least one contact foil (4) contacts the contact section (9) respectively with a radial contact normal force of at least 1 N, preferably at least 5 N.

6. The lamella body (3) is formed as a lamella cage (13) with a plurality of contact lamellas (4), The lamella cage (13) is in particular formed in a closed annular shape.

6. A plug-in connector arrangement according to any one of claims 1 to 5.

7. 7. The plug-in connector device according to claim 1, wherein the first position (P1) and the second position (P2) are spaced apart from each other along the plug-in direction (E) by a maximum of 5 mm, preferably by a maximum of 2 mm, particularly preferably by a maximum of 1 mm.

8. 8. The plug-in connector arrangement according to claim 1, wherein in the first position (P1), the radial play between the at least one contact foil (4) and the contact element (6) is in the range of 5 μm to 200 μm or in the range of 20 μm to 100 μm.

9. 9. The plug-in connector arrangement according to claim 1, wherein the at least one contact foil (4) is bent towards the contact element (6) in at least a predetermined section in the first position (P1).

10. said contact element (6) is a circular contact, or The contact element (6) is a flat contact or a contact blade.

10. The plug-in connector arrangement according to claim 1.

11. A support element (14), in particular of an annular shape, is arranged on the base element (7), the foil body (3) is supported at its first end section (11) on the support element (14), and / or an inner wall (15) of the support element (14) configured to center the contact element (6) in the contact chamber (2); 11. A plug-in connector arrangement according to any one of claims 1 to 10.

12. the sleeve element (8) has an inwardly directed protrusion (18) on the front sleeve element section (16) facing the counter plug-in connector (5), in particular on its front sleeve element free end (17), the foil body (3) is supported at its second end section (12) on the protrusion (18), and / or an inner wall (19) of the protrusion (18) is configured to center the contact element (6) within the contact chamber (2); 12. A plug-in connector arrangement according to any one of claims 1 to 11.

13. the base element (7) is made to a large extent of or consists of metal or plastic, and / or the sleeve element (8) is made predominantly of or consists of metal or plastic, 13. A plug-in connector arrangement according to any one of claims 1 to 12.

14. The base element (7) is electrically connected to an electrical line (20), The foil body (3) is electrically connected to the base element (7).

14. A plug-in connector arrangement according to any one of claims 1 to 13.

15. A plug-in connector, in particular for high-current and / or high-voltage applications, for plug-in connection with a counter plug-in connector (5) having contact elements (6), The plug-in connector (1) has a contact chamber (2) and a foil body (3) with at least one contact foil (4), The contact chamber (2) comprises a base element (7) and a sleeve element (8), the sleeve element (8) is arranged in particular non-detachably on the base element (7) and is displaceable relative to the base element (7) along the insertion direction (E) between a first position (P1) and a second position (P2), The foil (3) is arranged between the base element (7) and the sleeve element (8), in particular so as not to be detachable, In the first position (P1) of the sleeve element (8), the contact element (6) and / or the counter plug-in connector (5) are displaceable relative to the plug-in connector (1) along the plug-in direction (E) with a force of less than 5 N, in particular without any force; and / or A radial play is formed between the at least one contact foil (4) and the contact element (6), In the second position (P2), the at least one contact foil (4) is displaced radially inward in at least a predetermined section, and the foil body (3) is pressed between the sleeve element (7) and the base element (8), in particular so that the at least one contact foil (4) is electrically contact-connected to the inserted contact element (6) in the contact section (9), The plug-in connector (1) is configured in particular such that, when the plug-in connector (1) is mated with the counter plug-in connector (5) to the final mating position (ES), the sleeve element (8) abuts against an abutment structure (10) of the counter plug-in connector (5), thereby causing the plug-in connector (1) to be displaced to the second position (P2). Plug-in connector.

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