electrical connectors

Abstract

To provide an improved high power connector for a dynamic environment.SOLUTION: An electrical connector 1 includes at least two electrical contacts 13a, 13b housed in an internal connector space 45 and configured to mate with corresponding electrical contacts 113a, 113b of a second connector 101. The electrical connector 1 includes a lever 49 which is housed in the internal space so as to establish a supporting point 51 between the housing and the lever 49. The supporting point is located so as to be disposed between the at least two electrical contacts. Further, the lever is arranged and configured so that pivoting of the lever moves positions of the at least two electrical contacts relative to the housing.SELECTED DRAWING: Figure 2A

Description

[Technical Field]

[0001] The present invention relates to an electrical connector configured to mate with a second connector, particularly an electrical connector for high power vehicle applications. [Background technology]

[0002] When the contact surfaces of metal electrical contacts come into contact, the surface asperities of each surface become intimately attached. Relative sliding between the contact surfaces causes the breakdown of the intimately attached surface asperities, which results in the generation of wear debris. The term fretting corrosion refers to the generation of such wear debris and subsequent oxidation of the contact surfaces of metal electrical contacts under mechanical load.

[0003] Fretting corrosion increases contact resistance, which can impede the transmission of electrical signals and cause power loss, especially to heat. Fretting corrosion also degrades the material properties of the corroded material under stress, such as fatigue strength. For example, fretting corrosion can increase the risk of crack initiation.

[0004] Meanwhile, as a result of industry-wide efforts toward the electrification of mobility, electrical connectors are increasingly being implemented in vehicle applications for not only signal transmission but also power transmission: for example, high-power connectors may be required to safely and reliably transmit DC currents of 50 A or more.

[0005] At the same time, the dynamic environment in many types of vehicles, particularly trains and aircraft, can create significant vibration loads on power transfer components. For example, continuous vibrations with vibration amplitudes ranging from a few micrometers up to 10 mm are common in aircraft.

[0006] Vibrations are transmitted from a vibration source to an electrical connection consisting of an electrical connector mated with a second electrical connector, particularly a plug connector mated with a receptacle connector. As a result, the mated, bottomed, and fixed portions of the respective connector housings move together. However, especially considering variations in contact dimensions within manufacturing tolerances, the mated electrical contacts of the respective connectors can still move relative to each other and their respective housings, resulting in fretting corrosion.

[0007] This vibration-induced fretting corrosion of electrical connectors results in an undesirable increase in ohmic contact resistance and undesirable energy loss as heat.

[0008] For this reason, to this day, high-power electrical connections are secured using high-voltage compression lug connections. Lug connections typically include uninsulated, exposed parts that pose a safety risk to humans under high voltages and a risk to the vehicle due to electromagnetic radiation. In particular, the lack of insulation on the exposed parts limits the power transmitted, depending on the insulation resistance of the surrounding gas, which can vary with the humidity level of the environment. Lugs must be tailored for relatively low-voltage applications, since they are insulated only by the air gap between adjacent lugs and the aircraft's metal structure.

[0009] Furthermore, installing lug connections can be time-consuming and labor-intensive. Specialized tools are required for stamping deep cables and securing the initial connections. A series of markings is often required to indicate completed installation steps. Heavy metal, high-power cables and lugs are particularly cumbersome to manipulate, as additional loops of excess cable are typically allocated to accommodate any lug connection repairs that may be required. Concomitantly, these additional cable loops increase the vehicle's total mass, thus reducing energy efficiency.

[0010] Additionally, thermal expansion, vibration, and compressive stresses all wear the lug connections, which may require frequent refastening to ensure continued safe operation of the connection. Preventive maintenance requirements, including checking and retightening the fastenings, therefore become a cost factor in vehicle operation. Summary of the Invention [Problem to be solved by the invention]

[0011] In light of the above, it is an object of the present invention to provide an improved high power connector for dynamic environments. [Means for solving the problem]

[0012] This object is achieved by an electrical connector, particularly an electrical connector for high power vehicle applications, comprising: a housing configured to mate with a second connector in a parallel mating direction along a mating axis, the housing defining an interior connector space and configured to mate with a mating housing of the second connector; and at least two electrical contacts housed in the interior space of the housing and configured to mate with corresponding electrical contacts of the second connector.

[0013] The electrical connector further comprises a lever housed in the interior space of the housing such that mechanical contact between the housing and the lever establishes a fulcrum for the lever, the fulcrum being positioned to be located between the at least two electrical contacts, and the lever is further arranged and configured such that pivoting of the lever causes the positions of the at least two electrical contacts to move relative to the housing.

[0014] When an electrical connector according to the present invention is mated with a second mating connector, the lever can shift the position of the electrical contacts relative to the housing to compensate for differences in contact length within manufacturing tolerance limits. For example, manufacturing tolerance limits may allow for deviations of −0.5 mm and +0.5 mm from the nominal length. In particular, when a first electrical contact bottoms out with a corresponding mating electrical contact in the second connector, translation of the connector housing during connector mating exerts a force on the lever through the first bottomed contact. The lever then pivots about the fulcrum, thereby adjusting the relative positions of the more distant electrical contacts about the fulcrum until they also bottom out.

[0015] The electrical connector of the present invention, without the need for lugs, can reduce or even eliminate relative movement between mating electrical contacts, a source of fretting, and therefore is more resistant to fretting corrosion when mated with a mating connector, even in high-vibration environments. This allows for faster and easier installation and maintenance, as well as higher power performance, higher voltages, and better electromagnetic compatibility due to lighter vehicle weight. For example, the first connector can be a receptacle connector and the second connector can be a plug connector, or vice versa, particularly for plug and receptacle connectors used in aerospace environments. This allows the present invention to be applied to high voltage, high vibration aerospace environments where fretting corrosion is particularly likely to occur.

[0016] The electrical connector can be further improved according to various advantageous aspects which may be independent of one another in terms of their respective technical effects and which may be combined in any way.

[0017] In one aspect of the invention, the housing may further comprise a shell and a pusher element, the pusher element being disposed in the interior space and rigidly attached to the shell of the housing, particularly form-fitting, the pusher element providing mechanical contact between the housing and the lever at the fulcrum, such that when the housing shell is manually moved to operate the mating and coupling of the electrical connector with a mating second connector, the movement of the shell can be directly transmitted from the pusher to the lever via the fulcrum.

[0018] In one aspect of the invention, the lever may be configured such that pivoting of the lever causes the positions of the at least two electrical contacts to move parallel to the mating axis relative to the housing, which can improve control of the movement of the electrical contacts to compensate for length differences and reduce fretting corrosion.

[0019] In one aspect of the invention, the lever may include a protrusion, particularly a hemispherical protrusion or bulge, that protrudes from the face of the lever in a direction opposite to the mating direction, the tip of the protrusion being a mechanical contact point with the housing that establishes a fulcrum. This may advantageously focus movement of the shell and pusher toward the lever at a single connection location, allowing the lever to pivot freely about the protrusion while reducing damage, friction, or chafing.

[0020] In one aspect of the invention, each electrical contact is held in a corresponding contact sleeve, which may be form-fit and / or friction-fit, and each contact sleeve has at least one shearing portion on its exterior, the shearing portion configured to establish mechanical contact with the lever. In this configuration, the contact sleeve may be a protective casing for the contact, capable of receiving mechanical forces from the lever without impairing or interfering with the function of the electrical contact.

[0021] In one aspect of the invention, the shear portion may comprise a protrusion having a load surface facing in a direction opposite to the mating direction, the load surface being configured to receive a mechanical load from the lever, thereby improving the mechanical contact between the contact sleeve and the lever.

[0022] In one aspect of the invention, each load surface of a respective contact sleeve may abut a respective load tip of the lever. By establishing mechanical contact between the lever and the contact sleeve at the tip of the lever, the leverage or mechanical advantage of the lever is improved.

[0023] In one aspect of the invention, the load tip of the lever may rest freely on the respective load surface of the sleeve, allowing the load tip to slide on the load surface. In this configuration, the load tip sliding on the load surface as the lever pivots can act as a cam. Thus, linear motion is imparted to the contact sleeve, which acts as a cam follower.

[0024] In one aspect of the invention, the lever may be configured to pivot about a fulcrum within a predetermined maximum angular displacement range, the predetermined maximum angular displacement range being defined by a path limiting means on the housing that limits the movement of the lever. Thus, the displacement of the lever in the connector shell can be limited to a desired range without interfering with the design and function of the connector.

[0025] In one aspect of the invention, the connector may further include at least one safety pin movable between a secure position and an unsecured position, wherein in the unsecured position, the safety pin is configured to prevent mating of the connector with a second electrical connector, particularly by protruding from the housing in a mating direction to block the second electrical connector. A safety pin configured in this manner can prevent unsecured or unintended connector mating, for example, when components of the connector housing are improperly mated or poorly installed.

[0026] In one aspect of the invention, the connector may further include a corresponding safety pin for each contact sleeve, each safety pin movable between a respective secured position and a respective unsecured position, and in the unsecured position, each safety pin is configured to prevent mating of the connector with the second electrical connector, particularly by protruding from the housing in the mating direction to block the second electrical connector, thereby individually protecting the attachment of each contact to its corresponding sleeve and the attachment of each sleeve to the connector housing, and preventing mating if one of the attachments is insufficient.

[0027] In one aspect of the invention, the shell may have a circular shape in a plane perpendicular to the mating axis, and a surface of the shell may include a mechanical coupling device, particularly a thread or a friction fit or clip fastening device, for coupling the connector with a mating mechanical coupling device, particularly a mating thread or a friction fit or clip fastening device, of the second connector. Such coupling can secure the connection between the first and second electrical connectors. In particular, mating the connectors with threads allows for better control of the mating process and allows for lever pivoting if necessary due to differences in the lengths of the electrical connectors during mating.

[0028] In one aspect of the present invention, each electrical contact may be held in an internal cavity of a corresponding contact sleeve, each internal cavity including a sealing element arranged to seal an opening of the internal cavity, and in particular, the sealing element may be a triple barrier grommet, a gland seal, or a bushing seal, to prevent water from entering and contacting the conductive surfaces of the electrical contacts.

[0029] The object of the present invention can also be achieved by an electrical connector assembly including the electrical connector according to any one of the above-described aspects and a second connector. The second connector includes a mating housing configured to mate with the housing of the electrical connector and corresponding electrical contacts configured to mate with the electrical contacts of the electrical connector, and the lever pivots about a fulcrum so that each contact bottoms out against its corresponding electrical contact. This assembly enables a high-power electrical connection while reducing fretting corrosion due to the advantages of the above-described connector.

[0030] In one embodiment of the assembly, the second connector may be an electrical connector according to one of the above-described embodiments. When both electrical connectors are connectors according to the above-described embodiments, the positions of the corresponding mating electrical contacts of the mating second electrical connector may be adjusted in conjunction with the positions of the electrical contacts of the electrical connector. In this configuration, one connector may have male electrical contacts and the other connector may have female contacts, or vice versa, and bottoming may occur between the terminal or distal end faces of the male and female electrical contacts.

[0031] The object of the present invention can further be realized by a lugless electrical connector assembly, particularly for high power applications using currents of 50 A or more, particularly 200 A or more, comprising a first electrical connector, particularly an electrical connector according to any one of the above aspects, adapted to mate with a second electrical connector along a mating axis. The first electrical connector comprises a first housing defining an interior connector space adapted to mate with a mating second housing of the second connector.

[0032] The first electrical connector further comprises at least two first electrical contacts accommodated in the internal connector space and mating with corresponding electrical contacts of the second connector, wherein an end face, particularly a distal end face, of each of the first electrical contacts at least partially abuts a respective mating side face of the corresponding electrical contact receptacle, and the abutment of all electrical contact pairs is fixed by an inclined positioning of the first housing relative to the mating second housing with respect to the mating axis.

[0033] The lugless assembly allows differences in the length of the electrical contacts within manufacturing tolerances to be compensated for by tilting the first connector housing relative to the second connector housing. If one of the electrical contacts is longer than the other so that its end face first abuts the mating side of the corresponding contact receptacle during mating, the first housing can be tilted to accommodate the difference in length. In particular, the first housing can be tilted so that the shorter electrical contact or contacts move forward until they abut the mating side of their respective contact receptacles.

[0034] In one embodiment of the lugless electrical connector assembly, the housing of a first electrical connector may be mated, particularly threaded, to a second connector, and tilting of the first housing relative to the mating second housing is enabled by a clearance between a first mechanical coupling device of the first electrical connector and a second mechanical coupling device of the second connector, particularly where the first mechanical coupling device is male threaded and the second mechanical coupling device is female threaded. The clearance allows the first housing to tilt relative to the second housing along the mating axis without damaging the housing. In particular, the clearance limits the tilting to a predetermined maximum angular displacement depending on the clearance between the first and second mechanical coupling devices.

[0035] In one embodiment of the lugless electrical connector assembly, in the tilted orientation, the facing surfaces of the first and second housings may only partially abut, which may allow the first connector to be tilted relative to the second connector until contact bottoming is achieved without jeopardizing the security of the connector assembly lock.

[0036] In one aspect of the lugless electrical connector assembly, the housings of the first and second electrical connectors may have a rectangular shape in a plane perpendicular to the mating axis, the housing of the first electrical connector including a plug, and the housing of the second electrical connector including a mating receptacle extending centrally therethrough and configured to receive and mate with the plug. In this configuration, coupling of the electrical connector with the second connector can be achieved by a mechanical coupling device, such as by threading a threaded plug into a threaded receptacle, which can provide pivotal movement of a lever during mating if required due to differences in the lengths of the electrical contacts.

[0037] The object of the present invention is also realized by a lugless electrical connector assembly, particularly for high power applications using currents of 50 A or more, comprising a first electrical connector for mating with a second electrical connector along a mating axis, the first electrical connector comprising a first housing defining an internal connector space and mating with a mating second housing of the second connector, the first electrical connector comprising electrical socket contacts received in the internal connector space and mating with corresponding electrical contacts of the second connector, wherein end faces, particularly distal end faces, of the first electrical contacts at least partially abut against respective mating end faces, particularly distal end faces, of the corresponding electrical contacts, and wherein the shell end faces of the first housing do not abut against respective shell end faces of the second housing.

[0038] The lugless connector assembly ensures that bottoming of the first and second electrical connectors occurs at their respective electrical contacts, rather than at the connector housing. Because mating forces are primarily applied to the mating, face-to-face contact surfaces, any relative motion caused by vibration is reduced or eliminated. As a result, the occurrence of fretting corrosion is reduced or eliminated.

[0039] In one embodiment of the assembly, the electrical socket contacts may be held in a first contact sleeve, particularly a removably form-fit and / or friction-fit, which in turn removably form-fits and / or friction-fits the first housing, and / or the corresponding electrical contacts are held in a second contact sleeve, particularly a removably form-fit and / or friction-fit, which in turn removably form-fits and / or friction-fits the second housing. The contact sleeve can function as a protective casing for the contacts and as an isolating device to isolate the energized contacts from other connector housing components. Removable sleeves can allow for periodic inspection and replacement of the electrical contacts for connection maintenance.

[0040] In one embodiment of the assembly, the first electrical connector may further include a first safety pin and / or the second electrical connector may include a second safety pin, each safety pin movable between a secure position and an unsecured position, wherein in the unsecured position, the safety pin prevents mating of the first and second electrical connectors, particularly by protruding from the respective housings toward the respective mating connectors. The safety pins can reduce the risk of unsecure or unintended connector mating, for example, if components of the first or second housing are improperly mated or poorly installed.

[0041] In one embodiment of the assembly, the first housing may include a first mechanical coupling device, particularly a female thread, and the second housing may include a second mechanical coupling device, particularly a male thread, and the first and second mechanical coupling devices are configured to allow the first and second electrical connectors to be coupled, particularly screwed together. The first and second mechanical coupling devices can help achieve coupling of the first and second electrical connectors.

[0042] The present invention also relates to a sleeve removal tool for removing electrical contact sleeves for electrical contacts in an electrical connector, in particular for removing a contact sleeve according to one of the aforementioned aspects from a connector according to one of the aforementioned aspects, the sleeve removal tool being insertable into a corresponding through-hole and configured to displace a safety pin, in particular a safety pin described in one of the aspects of the present disclosure, from a secured position to an unsecured position.

[0043] The objects of the present invention can further be realized by a method for lugless connection along a mating axis of a first electrical connector having at least one electrical contact provided in an interior connector space of a first housing with a mating second electrical connector having at least one mating electrical contact receptacle provided in an interior space of a mating second housing, the method comprising: a) abutting an end face, particularly a distal end face, of at least one electrical contact of the first electrical connector against a mating side face of at least one mating electrical contact receptacle of the second electrical connector; c) mechanically securing the electrical connection by achieving a friction-fit and / or form-fit connection between the first housing and the second housing; Includes.

[0044] By applying this method of lug-less connection of multiple connectors, the benefits of a fretting corrosion free connection can be realized.

[0045] In one aspect of the method, the first electrical connector has at least one first electrical contact disposed in an interior connector space of a first housing, and the second electrical connector has at least one mating second electrical contact receptacle disposed in an interior connector space of a mating second housing, the method includes: b) abutting an end face, particularly a distal end face, of a second electrical contact of the first electrical connector against a mating side of a second electrical contact receptacle of the second electrical connector while keeping an end face, particularly a distal end face, of the first electrical contact in abutment against a mating side of the mating first electrical contact receptacle. It may further include:

[0046] This method may make it possible to obtain a fretting corrosion free connection in a scenario where two contacts are held in a single connector housing.

[0047] According to another aspect of the present invention, which may be combined individually or in combination with one of the above-mentioned aspects, the object of providing an improved connector for dynamic environments, in particular a high-power connector, is also realized by an electrical connector for high-power applications, in particular with a current of 50 A or more, configured to mate with a second connector along a mating axis, comprising a housing and at least one contact sleeve accommodated in the housing, the contact sleeve being configured to accommodate electrical contacts, the contact sleeve being movable in the housing between a locked position and an unlocked position, in which the contact sleeve, in particular together with the electrical contacts, can be removed from the housing. In contrast, in the locked position, the contact sleeve is correctly positioned and firmly attached to the housing.

[0048] This aspect of the invention allows for inspection and / or replacement of the contact sleeve without having to completely replace the connector itself.

[0049] The electrical connector further comprises at least one safety pin movable between a secure position and an unsecured position, in which the safety pin is configured to prevent mating of the connector with the second electrical connector, particularly by protruding from the housing in the mating direction to block the second electrical connector, so that an electrical connection cannot be established between the electrical connector and the second connector when the contact sleeve having the electrical contacts is in the unlocked position.

[0050] In contrast, the safety pin may be further configured to establish an electrical connection between the electrical connector and the second connector when the contact sleeve is properly positioned in the locked position. Preferably, in the safe position, the safety pin does not protrude from the housing in the mating direction, thereby allowing mating between the connectors.

[0051] The safety pin ensures that the connector can only be mated if the contact sleeve is correctly assembled with the housing. According to one embodiment, the safety pin is mechanically prevented from moving from the unsecured position to the secured position by the contact sleeve, in particular by a protrusion on the outside of the contact sleeve, unless the contact sleeve has already been moved to the locked position.

[0052] Thus, the safety pin can only be moved to the safety position when the sleeve is properly assembled with the housing.

[0053] According to one embodiment, the safety pin may be configured to prevent the contact sleeve from moving from the locked position to the unlocked position when in the safety position, thereby preventing undesired disassembly.

[0054] In one embodiment, the electrical connector may comprise a spring arrangement configured such that in the non-secure position, the spring arrangement is loaded, in particular by a protrusion on the outside of the contact sleeve, and the spring arrangement moves to the safe position by a spring restoring force, in particular thereby moving the safety pin from the non-secure protruding position to the safe non-protruding position.

[0055] In one embodiment, the movable safety pin may be disposed in the housing along the insertion direction of the contact sleeve during assembly of the electrical connector, such that the preloaded spring arrangement counteracts the insertion movement of the contact sleeve as long as the contact sleeve is in the unlocked position, thereby causing the contact sleeve to repel in the housing in a direction opposite to the insertion direction under a restoring force unless moved to the locked position.

[0056] In one embodiment, the electrical connector may include one corresponding safety pin for each contact sleeve, as described above.

[0057] These and other objects and advantages of the present invention will be more fully understood and appreciated from a careful consideration of the following more detailed description of the presently preferred exemplary aspects and embodiments of the invention in conjunction with the accompanying drawings. [Brief explanation of the drawings]

[0058] [Figure 1A] 1 is a perspective view of an electrical connector according to an embodiment of the first aspect of the present invention; [Figure 1B] FIG. 1B illustrates a connector configured to mate with the electrical connector of FIG. 1A. [Figure 1C] 1B shows the electrical connector of FIG. 1A and the second connector of FIG. 1B in an intermediate mated state. [Figure 1D] 1B is a different perspective view of the electrical connector of FIG. 1A, the connector having a retracted safety pin. [Figure 2A]1B is a first cross-sectional view of the electrical connector of FIG. 1A, FIG. 1D and the second connector of FIG. 1B in a mated state. [Figure 2B] 1C shows the arrangement of lever and pusher elements in the electrical connector of FIGS. 1A and 1B. FIG. [Figure 2C] 1C is a diagram showing the arrangement of levers and contact sleeves in the electrical connector of FIG. 1A and FIG. 1B. [Figure 2D] 1B is a second cross-sectional view of the electrical connector of FIG. 1A, FIG. 1D and the second connector of FIG. 1B in a mated state. [Figure 2E] 1A-1C are diagrams illustrating a method of connecting a first electrical connector and a second electrical connector according to the present invention without using lugs. [Figure 3A] 2B shows the contact area of ​​the cross section of FIG. 2A in an example where the electrical contacts of the electrical connector have a nominal length. [Figure 3B] 10A and 10B show contact areas in cross sections of the electrical connector in an example where the electrical contacts have a minimum length within manufacturing tolerances. [Figure 3C] 2B shows the contact area of ​​the cross section of FIG. 2A when the electrical contacts of the electrical connector have a maximum length within manufacturing tolerances. [Figure 3D] 2B shows the contact area of ​​the cross section of FIG. 2A when one contact has a minimum length and another contact has a maximum length within manufacturing tolerances. [Figure 4] 10A and 10B show a lever for an electrical connector according to a second embodiment of the first aspect of the invention. [Figure 5] 10A-10C show a connector assembly according to an embodiment of the second aspect of the present invention. [Figure 6] 5A to 5C show different embodiments of a connector assembly according to the second aspect of the present invention; [Figure 7A] FIG. 10 is a perspective view of a connector for a lugless connector assembly according to one embodiment of the third aspect of the present invention. [Figure 7B] 7B is a cross-sectional view of a lugless connector assembly including the connector of FIG. 7A. [Figure 8] 1C is a view of the second connector of FIG. 1B in relation to the removal of a contact sleeve using a sleeve removal tool. [Figure 9] 10A-10C are comparative diagrams of alternative pairs of electrical contacts. DETAILED DESCRIPTION OF THE INVENTION

[0059] 1A shows a perspective view of an electrical connector 1 according to a first embodiment of the present invention, which is configured to mate with a mating second connector, such as the second electrical connector shown in FIG. 1B, in a mating direction x parallel to a mating axis AX.

[0060] In this embodiment, the electrical connector 1 is a movable connector, also called a plug connector, that is manually mated with a fixed or non-movable mating second connector, also called a receptacle connector. For example, the electrical connector 1 is suitable for establishing a power transmission connection for a power cable in an electric vehicle, such as an electric aircraft.

[0061] The electrical connector 1 comprises a housing 3 including an inner shell 5 surrounded by an outer shell 7. The inner shell 5 and outer shell 7 have concentric cross sections. As will be further described below, the outer shell 7 is rotatably disposed about the inner shell 5. The outermost surface 9 of the outer shell 7 includes a textured surface 11 to enhance manual gripping for rotation of the outer shell 7 relative to the inner shell 5.

[0062] The electrical connector 1 further includes two electrical contacts 13a, 13b disposed inside the inner shell 5. In a preferred embodiment, the electrical contacts 13a, 13b are gold- or silver-plated copper contacts for improved electrical conductivity and corrosion resistance. In this embodiment, the electrical contacts 13a, 13b are female or socket contacts with cylindrical receptacles 15a, 15b configured to receive male contacts of a mating second connector. However, in alternative embodiments, the electrical contacts 13a, 13b may be male contacts to be received by corresponding female contacts.

[0063] The electrical contacts 13a, 13b extend parallel to the mating axis AX inside the housing 3, and the receptacles 15a, 15b are configured to receive mating male contacts extending in the opposite direction to the mating direction x.

[0064] The inner shell 5 has a circular opening facing the mating direction x, in which a thermoplastic electrically insulating object 17 is arranged to seal and electrically insulate the interior space of the inner shell 5 from the external environment. The insulating object 17 is arranged in a yz plane perpendicular to the mating direction x and has two hollowed cylindrical protrusions 19a, 19b, each having an opening 21a, 21b that provides a passage through the insulating object 17 to the interior space of the inner shell 5.

[0065] The electrical contacts 13a, 13b are disposed in protrusions 19a, 19b of the insulating body 17 such that the respective receptacles 15a, 15b of the contacts 13a, 13b mate with the openings 21a, 21b of the insulating body 17. In particular, the openings 21a, 21b are configured to receive the male electrical contacts of a mating second connector during mating and to provide abutment of the male distal end faces of the male electrical contacts with the female mating sides 22a, 22b of the connector 1, as will be further described below.

[0066] The interface 23 of the insulating body 17 serves as the contact surface with a mating second connector when mated. In the fully mated state, and when the electrical connection of the connector 1 with the mating connector is energized, the insulating body provides electrical insulation between the conductive elements, particularly between the electrical contacts 13 a, 13 b and the connector housing 3.

[0067] Two contact sleeves 25a, 25b (25a is not visible in FIG. 1A), also referred to as lock inserts, extend parallel to the mating axis AX in opposite directions to the mating direction x from the interior space of the inner shell 5. As will be described with reference to FIGS. 2A and 2B, the contact sleeves 25a, 25b are hollowed out to hold the electrical contacts 13a, 13b. The sleeves 25a, 25b are used to receive and lock the electrical contacts 13a, 13b in the housing 3.

[0068] 1A further shows serrated peripheral ridges 27 on outer shell 7, a metal band 29 for radio frequency interference filtering, and two safety pins 31 a, 31 b, which represent optional safety features that prevent connector 1 from mating with a second mating connector if electrical contacts 13 a, 13 b or contact sleeves 25 a, 25 b are not fully locked into inner shell 5.

[0069] 1A, the electrical contacts 13a, 13b or contact sleeves 25a, 25b are not fully locked in the housing 3, which is indicated by the safety pins 31a, 31b protruding from the housing 3 in the mating direction x. The safety pins 31a, 31b protrude to prevent mating with a mating second connector while the electrical contacts 13a, 13b are not fully locked in the housing 3. In particular, the protruding safety pins 31a, 31b are configured to abut against the housing of the mating second connector.

[0070] On the other hand, when the electrical contacts 13a, 13b and contact sleeves 25a, 25b are fully locked in the housing 3, the safety pins 31a, 31b are retracted inside the inner shell 5 by the preloaded spring arrangement. While the safety pins 31a, 31b are retracted inside the inner shell 5, they lock and secure the contact sleeves 25a, 25b, which hold the contacts 13a, 13b in place. When the contact sleeves 25a, 25b are in the locked and secured position, they can only be released again using a dedicated tool, which will be described in more detail with reference to FIG. 8. A diagram of the connector 1 with the locked and secured sleeves 25a, 25b is shown in FIG. 1D.

[0071] The metal band 29 is disposed on the outer surface of the inner shell 5 and is visible in the inter-shell space 33 between the concentric inner shell 5 and outer shell 7. Inside the inter-shell space 33, the shell threads of the outer shell 7 provide a threaded surface 35. Specifically, the threaded surface 35 is circumferentially disposed on the inner tubular wall of the outer shell 7. The threads extend along the mating axis AX and function for mating of the connector 1 in the mating direction x when engaged with a matching threaded portion of a mating second connector.

[0072] In this embodiment, the threaded surface 35 is a nut-side thread, or female thread, that forms a threaded receptacle configured to mate with a threaded, or male, thread on the exterior of a mating second connector, although in alternative embodiments, the electrical connector could include threads on the exterior of the inner shell 5 that mate with the nut-side threads of another mating second connector.

[0073] The peripheral ridge 27 faces in the opposite direction to the mating direction x and is saw-toothed, thereby presenting a plurality of triangular teeth. The teeth of the saw-tooth ridge 27 provide an interface for a fitment to be mounted on the connector 1 for controlling the tightening or screwing of each tooth of the connector 1 during mating and coupling with a mating second connector.

[0074] In addition, a centering key 37 is provided on the outer surface of the inner shell 5. The centering key 37 is arranged to form-fit with a mating feature of the mating second connector to simplify alignment with the mating second connector.

[0075] Figure 1B shows a second electrical connector 101, which is a mating second connector suitable for mating with the electrical connector 1 of the embodiment described with reference to Figure 1A. The second connector 101 is a fixed or immovable mating second connector, also referred to as a receptacle connector, and includes a mating housing 103 including a shell 105 and a base plate 107. The base plate 107 includes through holes 111 for screw fastening of the base plate 107 to, for example, a body panel.

[0076] At the outermost surface 109 of the shell 105, a threaded surface portion 135 is circumferentially arranged to provide a threaded side thread forming a threaded plug. The threaded surface portion 135 extends along the mating axis AX, thereby matching the threads of the threaded surface portion 35 of the electrical connector 1. In a variant of the invention, instead of the threaded surface portion 135, the surface portion may comprise, for example, a friction fit or a clip-on device.

[0077] A boundary insulating body 117, presenting a mating interface 123, is disposed inside the shell 105 of the housing 103. The boundary insulating body 117 is an elastomer configured to seal and electrically insulate the connection. The boundary insulating body 117 includes two cylindrical cavities 119a, 119b extending along the mating axis AX and crossing the interface 123 at cavity openings 121a, 121b. Male electrical contacts 113a, 113b are disposed in the cavities 119a, 119b of the insulating body 117 and are accessible through the cavity openings 121a, 121b. The contacts 113a, 113b are mating electrical contacts corresponding to the contacts 13a, 13b of the connector 1. The tips of the male contacts 113a, 113b include distal end faces 122a, 122b extending in a yz plane perpendicular to the mating direction x. Contacts 113a, 113b are retained in contact sleeves 125a, 125b which form-fit into housing 103, with only sleeve 125b being visible in FIG. 1B.

[0078] In one embodiment, each of the cylindrical cavities 119a, 119b in the insulating body 117 may include a plurality of, for example, three, ring-shaped ribs arranged circumferentially. When the protrusions 19a, 19b of the connector 1 are inserted into the respective cavities 119a, 119b, the electrical connection is water-sealed.

[0079] The insulating body 117 of the second connector 101 is mounted to the inner shell 5 of the connector 1 such that an annular intermediate space 133 is formed between the peripheral surface 129 of the insulating body 117 and the shell 105. The annular intermediate space 133 is configured to receive the inner shell 5 of the housing 3 of the connector 1 during mating of the connectors 1, 101.

[0080] Similar to the electrical connector 1, the second connector 101 includes two safety pins 131a, 131b configured to prevent mating if the electrical contacts 113a, 113b or contact sleeves 125a, 125b are not fully locked into the housing 103. In the view of FIG. 1B, the electrical contacts 113a, 113b and sleeves 125a, 125b are fully locked into the housing 103, as indicated by the safety pins 131a, 131b being retracted inside the inner shell 105. In particular, the safety pins 131a, 131b are retracted by a preloaded spring arrangement. If the electrical contacts 113a, 113b are not fully locked, the respective safety pins 131a, 131b extend in a direction opposite the mating direction x to prevent mating, as described and shown in the electrical connector 1 described with respect to FIG. 1A.

[0081] The peripheral ridges 127 of the shell 105 facing the mating direction are serrated, similar to the ridges 27 of the first connector 1. Furthermore, centering recesses 137 configured to receive the centering keys 37 of the connector 1 to establish a form fit are formed in the shell 105 facing toward the annular intermediate space 133. In particular, during mating, the form fit between the centering keys 37 and the centering recesses 137 prevents rotational movement between the inner shell 5 of the connector 1 and the shell 105 of the second connector 101, thereby allowing the connectors 1, 101 to be mated by threading the outer shell 7 around the shell 105 of the connector 101. Additionally, the keys 37 and the recesses 137 simplify proper coupling.

[0082] 1C shows the electrical connector 1 of FIG. 1A and the second connector 101 of FIG. 1B in an assembled, intermediate mated state. For visibility, corresponding angled portions of the outer shell 7 and inner shell 5 of the first connector 1 and of the shell 105 of the second connector 101 have been removed to visualize the internal components and illustrate the intermediate mated state.

[0083] 1C, the movable connector 1 is moved toward the second connector 101. As a result, the shell 105 of the second connector 101 is inserted into the inter-shell space 33 between the inner shell 5 and the outer shell 7 of the connector 1, and the inner shell 5 is inserted into the annular intermediate space 133 between the insulating body 117 and the shell 105 of the second connector. However, in this intermediate mated state, the threaded surface portion 35 of the outer shell 7 of the connector 1 has not yet reached the threaded surface portion 135 of the shell 105 of the second connector 101. Therefore, the male and female threads of the respective connectors cannot interlock, and mating cannot proceed.

[0084] Indeed, Figure 1C shows a hypothetical illustrative example in which contact sleeves 25a, 25b are not properly locked with their respective electrical contacts 13a, 13b in housing 1. For example, in the example of Figure 1C, contact 13a is absent or missing, and contact 13b is "loose," protruding outward from contact sleeve 25b in a direction opposite mating direction x. This indicates that contact 13b is only partially inserted and not fully locked into contact sleeve 25b. The illustrative position of contact 13b is intended only to illustrate incorrect locking into housing 1 and does not correspond to a typical steady state of contacts 13a, 13b in sleeves 25a, 25b.

[0085] 1C shows that wiring receptacle 39b is formed at the end of contact 13b. In particular, it is formed at the end opposite to the end at which receptacle 15b is formed. Wiring receptacle 39b is configured to receive wires of a high-power cable. The structure of wiring receptacle 39b is more clearly visible and described with respect to FIG. 2A.

[0086] 1C further shows that a sealing element 41a is provided in the internal cavity 26a inside the contact sleeve 25a. The sealing element 41a is used to seal the passage of a high-power cable inserted into the internal cavity 26a of the contact sleeve 25a, which will then be attached to the wiring receptacle of the electrical contact 13a. The sealing element 41a is a triple-barrier grommet that is particularly suited for round wires in high-power cables. Alternatively, a more robust sealing system, such as a gland / bush solution, may be used.

[0087] Because the contact sleeves 25a, 25b of the electrical connector 1 are not fully and properly locked in the housing 3, the safety pins 31a, 31b are fully extended, as also shown in FIG. 1A. Similarly, the safety pins 131a, 131b of the second electrical connector 101 are extended to protrude in the direction opposite to the mating direction x, indicating that the contacts 113a, 113b or sleeves 125a, 125b are not fully locked in the housing 103. The extended safety pins 131a, 131b abut the interface 23 of the insulating body 17 of the electrical connector 1, preventing the threads 35, 135 of the respective connectors 1, 101 from interlocking, thereby preventing mating unless one contact is properly and securely locked.

[0088] For illustrative purposes, Figure 1D shows electrical connector 1 from a different perspective than Figure 1A. In particular, Figure 1D shows connector 1 when electrical contact 13a is fully locked with contact sleeve 25a (not visible in Figure 1D) in housing 3 and properly positioned at protrusion 19a. Thus, and in contrast to Figure 1A, safety pin 31a is fully retracted into housing 3 and does not protrude from interface 23 of insulating body 17. Therefore, safety pin 31a does not prevent connector 1 from mating with a second mating connector, such as second electrical connector 101 as shown in Figure 2A.

[0089] Figure 2A shows a connector assembly 200 in a fully mated state, the assembly 200 comprising the above-described electrical connector 1 and a second electrical connector 101. Figure 2A shows a first cross-sectional view of the connectors 1, 101 along the x, y plane as shown in Figure 1C.

[0090] The cross-sectional view of FIG. 2A shows that a friction ring 42 is disposed between the substantially tubular inner shell 5 and outer shell 7. In particular, the friction ring 42 is circumferentially disposed around the inner shell 5 so as to be in partial frictional contact with the outer shell 7. The partial frictional contact creates increased resistance to undesired rotational movement of the outer shell 7 around the inner shell 5. The connector 1, 101 may further include an additional anti-separation device, such as a clicker nut system or a ball-lock system. The anti-separation device statically maintains the position of the outer shell 7 relative to the inner shell 5 in a given rotational state.

[0091] The inner shell 5 together with the insulating body 17 and the rear cover 43 define an interior connector space 45 of the connector 1 .

[0092] A pusher element 47 and a lever 49 are provided inside the interior connector space 45. The contact sleeves 25a, 25b retain the female electrical contacts 13a, 13b in their respective interior cavities 26a, 26b. The contact sleeves 25a, 25b extend at least partially into the interior connector space 45 through openings in the back cover 43. The pusher element 47 and the lever 49 mechanically contact at a single interface contact point that defines a fulcrum 51.

[0093] The structural features of pusher element 47 and lever 49, as well as their arrangement inside the interior connector space, are described in detail with respect to Figures 2B-2D.

[0094] The sleeves 25a, 25b lock the contacts 13a, 13b in place on the respective insulating body projections 19a, 19b of the insulating body 17 by a form-fitting arrangement. In particular, the contacts 13a, 13b are locked to the insulating body 17 by inner circumferential ledges 77a, 77b that mate with circumferential projections 79a, 79b on the outer surfaces of the contacts 13a, 13b. The ledges 77a, 77b and projections 79a, 79b are further described with respect to Figure 2D. Only when the contacts 13a, 13b are fully locked in place by the respective contact sleeves 25a, 25b do the safety pins 31a, 31b of Figure 1A retract inside the interior space 45.

[0095] Wiring receptacles 39a, 39b are formed at the distal ends of contacts 13a, 13b opposite the distal ends at which receptacles 15a, 15b are formed. Wiring receptacles 39a, 39b extend parallel to mating axis AX inside electrical contacts 13a, 13b and are configured to receive high-power conductor cable terminations. Through holes 81a, 81b in electrical contacts 13a, 13b lead to wiring receptacles 39a, 39b to facilitate visual confirmation of the positioning of wire terminations in wiring receptacles 39a, 39b of contacts 13a, 13b.

[0096] Additionally, each internal cavity 26a, 26b of each contact sleeve 25a, 25b is provided with a triple barrier grommet 41a, 41b configured to prevent water from entering and contacting the conductive surfaces when a high power conductor cable is installed in the contacts 13a, 13b.

[0097] In this embodiment, similar to the electrical connector 1, a pusher element 147 and a lever 149 are disposed in an interior space 145 of the second connector 101. Similar to the electrical connector 1, the interior space 145 is formed by the shell 105, the insulating body 117, and the rear cover 143. In addition, a secondary insulator 118, such as an insulating body 117 made of a thermoplastic material, disposed between the insulating body 117 and the contacts 113a, 113b provides further electrical insulation. However, in a modified example, the second connector may be a connector without the pusher element 147 and the lever 149.

[0098] In the mated state of FIG. 2A, the outer shell 7 is threaded onto the shell 105 of the second connector by mating threads 35, 135.

[0099] According to the present invention, the protrusions 19a, 19b of the insulating body 17 of the connector 1 are received in the cavities 119a, 119b of the second connector 101, thereby receiving the male contacts 113a, 113b of the second connector 101 in the receptacles 15a, 15b of the female contacts 13a, 13b. Furthermore, according to the present invention, the distal end faces 122a, 122b abut against the female mating surfaces 22a, 22b, thereby bottoming out the electrical contacts 13a, 13b with the respective male contacts 113a, 113b. Meanwhile, the housing 3 of the first connector 1 and the housing 103 of the second connector 101 are separated by a gap D1 between the end face 14 of the inner shell 5 and the mating end face 114 of the shell 105 of the second connector at the bottom of the inter-shell space 33. The surfaces 14, 114 are not bottomed out because they are separated by a gap D1.

[0100] As will be made clearer below, this is achieved by dimensioning the contacts 13a, 13b so that they abut before the housing 3, 103, in particular before the surfaces 14, 114. In particular, when the outer shell 7 is screwed into the shell 105 of the second connector 107, a rotational movement is transmitted as a translational movement to the pusher element 47, which is concentrated from the pusher element 47 via the fulcrum 51 onto the lever 49. The lever then distributes the mating force to the contact holding sleeves 25a, 25b according to the respective lengths of the contacts 13a, 13b, 113a, 113b within the manufacturing tolerances, i.e. according to the respective abutment positions of the contact pairs 13a-113a, 13b-113b along the mating axis AX, until all pairs 13a-113a, 13b-113b bottom out against each other.

[0101] 2B shows a perspective view of the lever 49 and pusher element 47 disposed inside the electrical connector 1. The pusher element 47 includes a straight cross beam portion 53 configured to diametrically traverse the interior space 45 defined by the inner shell 5. When mounted in the inner shell 5 as shown in FIGS. 2A and 2D, the cross beam portion 53 traverses the interior space 5 along a direction z perpendicular to the mating direction x and has a rectangular cross section in the yz plane.

[0102] At both ends along direction z, the pusher element 47 includes transverse arms 55a, 55b that extend from the pusher element 47 in the mating direction x and loosely surround the lever 49. Outer surfaces 57a, 57b of the transverse arms 55a, 55b are formed with recesses 59a, 59b to facilitate a form-fit of the pusher element 49 into the inner shell 5, as can be seen in Figure 2D, which is further described below.

[0103] The lever 49 has a flat rectangular parallelepiped shape with two semi-cylindrical cutouts 61a, 61b formed from two opposite sides of the rectangular parallelepiped shape. The cutouts 61a, 61b are configured to receive the contact sleeves 25a, 25b. The cutouts 61a, 61b are cut into the rectangular parallelepiped so that four arms 63a, 63b, 63c, 63d are formed, one at each distal corner of the rectangular parallelepiped. Each of the arms 63a, 63b, 63c, 63d includes a respective rounded load end 65a-65d that protrudes in the mating direction x.

[0104] Peripheral cutouts 64a, 64b, 64c are cut in the rectangular parallelepiped along the peripheral walls of the semi-cylindrical cutouts 61a, 61b. The cutouts 64a, 64b, 64c facilitate passage of shearing protrusions formed on the outer surfaces of the contact sleeves 25a, 25b when the sleeves 25a, 25b are inserted over the lever 49 during installation, as shown in FIG. 2C. Thus, the contact sleeves 25a, 25b and electrical contacts 13a, 13b can be interchanged within the same connector, if necessary.

[0105] The top surface 67 of the lever 49 facing away from the mating direction x has a hemispherical bulge 69 at or near its center. Alternatively, the bulge 69 may be hemispherical or have a different rounded shape that protrudes in the direction opposite to the mating direction x.

[0106] The pusher element 47 is disposed across the lever 49 along a plane of mirror symmetry extending along the plane zx of the lever 49, facing the top surface 67. The pusher element 47 extends between the cutouts 61 a, 61 b ​​so as to allow insertion of the sleeves 25 a, 25 b without covering the cutouts 61 a, 61 b. The lever 49 and the pusher element 47 are in mechanical contact at a single interface point at the apex 51 of the hemispherical bulge 69 relative to the top surface 67 of the lever 49. Thus, the fulcrum 51 for the pivoting of the lever 49 on the pusher element 47 is realized. In particular, as described with respect to FIG. 2C, a force F exerted on the lever by pusher element 47 at point 51 can generate a reaction force at any of load tips 65a, 65b, 65c, 65d (65c, 65d are not visible in FIG. 2B but are visible in FIG. 2C) when they are engaged.

[0107] 2C shows a perspective view of the lever 49 and contact sleeves 25a, 25b disposed inside the electrical connector 1. The pusher element 47 is only partially shown. In this view, the contact sleeve 25a and the contact 13a held in the sleeve 25a are partially opened to show the internal mechanism.

[0108] As can be seen in the partially opened portions of the sleeve 25a and the contact 13a, the contact 13a has a cylindrical shape extending in the mating direction x. The cylindrical shape is hollowed out at its front end facing the mating direction x to form a mating receptacle 15a having a female mating surface 22a. The surface 22a is configured to bottom out against the male distal end surface 122a of the contact 113a. The contact 13a is hollowed out at its rear end facing away from the mating direction x to form a wiring receptacle 39a having a through hole 81a.

[0109] Each sleeve 25a, 25b includes a shear portion 71a, 71b on its outwardly facing surface 38a, 38b, to which mechanical shear forces are transferred. In this embodiment, the shear portions 71a, 71b include block-shaped shear protrusions 73a, 73b that interface with the load tips 65b, 65c of the levers 49 so that mechanical shear forces or loads can be transferred to and from each other.

[0110] Each of the block-shaped shear projections 73a, 73b has a load surface 75b facing away from the mating direction x. The load tips 65b, 65c of the lever 49 rest freely on the respective load surfaces 75a, 75b of the shear projections 73a, 73b. As a result, as the lever 49 pivots about the z-axis as indicated by the double-headed arrow, the load tips 65b, 65c slide along the load surfaces 75a, 75b, while transmitting force along the axis x and vice versa. Thus, the pivoting movement of the lever 49 is translated into longitudinal movement of the sleeves 25a, 25b.

[0111] During mating and coupling of the connectors 1, 101, a mating force F is applied to the bulge 69 by the pusher element 47, which form-fits the inner shell 5, so that as the connector 1 advances toward the second connector 101, the contacts 13a, 13b advance with the connector 1. Specifically, the mating force is applied to the bulge 69, which is centrally located on the top surface 67 of the lever 49. The force F moves the lever 49, and thereby the contacts 13a, 13b, forward until bottoming out of the first contact is reached. For example, if contact 13b has a maximum length within a manufacturing tolerance, such as N+0.5 mm, and contact 13a has a nominal length N, contact 13b may first bottom out against its mating contact 113b as surfaces 22b, 122b abut.

[0112] As the first contact bottoms out and mating of the connectors 1, 101 continues, the load tip 65c presses against the load surface 75b, applying a reaction force C1 to the load tip 65c in a direction opposite to the mating direction x. This causes the lever 49 to pivot about the axis z at the fulcrum 51, causing the load tip 65b to rotate with the lever and move at least partially in the mating direction x, pushing the shear protrusion 73a in. The load tip 65b therefore moves the contact sleeve 25a in the mating direction against the resistance of the sleeve 25a's weight until the contact 13a bottoms out against the corresponding contact 113a on the mating contact surface 22a, 122a.

[0113] Each contact sleeve 25a, 25b further includes an inner peripheral ledge 77a that mates with a circumferential protrusion 79a on the outer surface of the respective contact 13a, 13b. The ledge 77a prevents the sleeve 25a, 25b from sliding over the respective contact 13a, 13b at a predetermined depth inside the respective internal cavity 26a, 26b of the sleeve 25a, 25b. In particular, the matching ledge 77a and protrusion 79a are formed on the sleeve 25a and contact 13a, respectively, such that the end of the contact 13a with the wiring receptacle 39a is retained inside the internal cavity 26a of the sleeve 25a, and the end of the contact 13a with the mating receptacle 15a is retained outside the sleeve 25a.

[0114] In an alternative embodiment, the contact sleeves 25a, 25b may be simplified by omitting the inner circumferential ledge 77a from the inner surface of the sleeves 25a, 25b. In this configuration, the circumferential protrusions 79a, 79b on the outer surface of each contact 13a, 13b may extend outwardly to intercept directly at the edge of the tubular wall of the sleeves 25a, 25b.

[0115] 2D shows a second cross-sectional view of the connector 1, 101, here along the xz plane as shown in FIG. 1C. As in FIG. 2A, the connectors 1, 101 are in a fully mated state. The insulating body 117 of the second connector 101 abuts the insulating body 17 of the connector 1, so that the interface 23 and the mating interface 123 are in contact. The threaded surface 35 of the outer shell 7 is threaded into the threaded surface 135 of the shell 105. The safety pins 31a, 131a are retracted into their respective interior connector spaces 45, 145.

[0116] Figure 2D, together with Figure 2A, shows the arrangement of the interior connector space 45 of the first connector defined by the shell 5, the insulating body 17, and the rear cover 43. In particular, Figure 2D shows the arrangement of the lever 49 relative to the pusher element 47 and the contact sleeves 25a, 25b.

[0117] The form-fit connection between the inner shell 5 of the connector 1 and the pusher element 47 is achieved by recesses 59a, 59b in the transverse arms 63a, 63b of the pusher element 47, which form-fit into mating recesses 83a, 83b formed in the inner shell 5. The pusher element 47 contacts the lever 49 at a fulcrum 51 at the apex of the bulge 69. The load tip 65d of the lever 49 rests freely on a load surface 75d of a shear projection 73d formed in the sleeve 25b. The opposite load tip 65c of the sleeve 25b rests on a corresponding load surface 75c of the projection 73c. ​​The load surface 75c and the projection 73c are hidden by the stabilizing element 76 of the insulating body 17.

[0118] 2D shows that in this embodiment, the mating second connector 101 includes a corresponding arrangement of pusher elements 147 that form-fit into shell 105, with lever 149 connecting with pusher element 147 at fulcrum 151 provided by bulge 149 on lever 149. Additionally, although not visible in this embodiment, contact sleeve 125b interacts with lever 149 in a manner similar to that described above, and thus second connector 101 enjoys the same advantages as connector 1. However, in an alternative arrangement, second connector 101 may lack these elements and have a conventional arrangement of sleeves and contacts.

[0119] The mating sequence and the role of lever 49 and pusher element 47 will now be explained in more detail with reference to Figure 2E, which shows schematically how a first electrical connector E1 having two electrical contacts E13a, E13b can be connected to a mating second electrical connector E101 having two electrical contacts E113a, E113b without the use of lugs.

[0120] Contacts E13a, E13b, E113a, and E113b are provided in the interior connector spaces of respective connector housings, which are omitted from FIG. 2D for simplicity. Each of contacts E13a, E13b, E113a, and E113b has a contact length that falls within a manufacturing tolerance range. The manufacturing tolerance range relates to limitations in manufacturing precision and consistency. Thus, the electrical contacts have a non-zero length difference. In FIG. 2E, contacts E113a and E113b have a length difference Δ, with contact E113b being longer than contact E113a.

[0121] In a first step A, the first connector E1 is approached toward the second connector E101. The first connector E1 is approached toward the second connector E101 until bottoming out of the first contacts occurs. As the first connector E1 is approached toward the second connector E101, the distal end faces E22b of the electrical contacts E13b first abut against the mating side faces E122b of the mating contacts E113b. Thus, bottoming out of the first contacts is achieved before any bottoming out of the housing or shell of the connectors E1, E101.

[0122] In a second step B, once one distal end face E22b of the first contact E13b abuts, further advancement of the connector E1 relative to the other connector E101 causes pivoting of the lever E149 connected to the contact E113b and the housing of the connector E101, resulting in a mechanical load. The pivoting of the lever E149 causes the second, not yet abutted, contacts E13a, E113a to approach each other until they bottom out. At the same time, the faces E22b, E122b remain abutted as the connector E1 continues to advance toward E101.

[0123] In a third step C, after lever 149 has pivoted to bottom out each electrical contact pair E13a-E113a, E13b-E113b, the pivoted arrangement is mechanically fixed. For example, the arrangement may be fixed by a friction ring, such as ring 42, which provides a friction-fit connection between the rotating parts of the threaded housing. Thus, the bottoming out of each contact pair E13a-E113a, E13b-E113b is fixed even when subjected to vibration. Other means of fixing the connection may also be used, in particular fixing means based on a form fit and / or a friction fit, such as a snap-fit ​​connection.

[0124] The above-described method may be particularly applied to connecting the above-described connectors 1, 101. Thus, as the connector 1 is mated by threading the outer shell 7 into the shell 105 of the second connector 101, the force acting on the fulcrum 51 is distributed to the contact sleeves 25a, 25b until the first contact of either contact 13a or 13b bottoms out. At this point, the force is effectively transferred to the respective second contact of either contact 13a or 13b until all contacts are fully bottomed out against their respective contacts 113a, 113b. Thus, bottoming out of the connector 1, 101 is achieved directly at the electrical contact pairs 13a-113a, 13b-113b, rather than at the housing 1, 3.

[0125] This is further illustrated with respect to Figures 3A-3D, which depict four different electrical contact configurations. Figures 3A-3D show cross-sectional views of the contact area of ​​the connector 1, 101 in a fully mated state for different electrical contact length scenarios. The four illustrated example scenarios correspond to cases that might typically result from contact length variations within manufacturing tolerances. These variations increase the risk of fretting vibrations. However, as explained below, in each of these examples, the assembly 200 is able to secure the contact bottoming out on the mating side before any of the faces of the shells 5, 7, 105 of the connector 1, 101 abut.

[0126] Cross-sectional views 3A-3D correspond to cuts in the xy plane as shown in Figure 2A. In particular, in Figure 3A, electrical contacts 113a, 113b both have a nominal length N, and end faces 14, 114 of connectors 1, 101 are separated by a gap D1. Thus, Figure 3A corresponds to a cut of Figure 2A that focuses only on the contact area.

[0127] In Figure 3B, the electrical contacts 113a', 113b' have a minimum length within manufacturing tolerances, for example N-0.4 mm. The connectors 1, 101 are separated by a gap D2.

[0128] In Figure 3C, the electrical contacts 113a'', 113b'' have a maximum length within manufacturing tolerances, for example N+0.4 mm. The connectors 1, 101 are separated by a gap D3.

[0129] In Figure 3D, one electrical contact 113a''' has a minimum length, for example N-0.4 mm, and the other electrical contact 113b''' has a maximum length, for example N+0.4 mm. The connectors 1, 101 are separated by a gap D4.

[0130] In all four configurations shown, the electrical contacts 13a, 13b of the connector 1 have the same nominal length for ease of illustrating the present invention, although deviations from the nominal length of the contacts 13a, 13b of the connector 1 may also be accommodated in accordance with the present invention.

[0131] In the example of Figures 3A and 2A, all contacts 113a, 113b, 13a, 13b have a nominal length of N + / - 0.0 mm. Distal end faces 122a, 112b abut against female mating surfaces 22a, 22b, and contact pairs 13a-113a and 13b-113b bottom out against each other. Because contact pairs 13a-113a and 13b-113b bottom out, a gap D1 exists between end face 14 of inner shell 5 and mating end face 114 of shell 105 of second connector 101. This gap D1 has a nominal value greater than the connector length tolerance, here, for example, greater than 0.5 mm.

[0132] As previously described, the mating force from the threaded connection is transmitted from the outer shell 7 to the sleeves 25a, 25b and from the sleeves 25a, 25b to the contacts 13a, 13b via the ledges 77a, 77b until the contact pairs 13a-113a and 13b-113b bottom out. Because the shells 5, 105 are sized to prevent bottoming out, all of the mating force is transmitted to the mating contact surfaces 22a-122a and 22b-122b. Therefore, the clearance gaps S1 between the sleeves 25a, 25b and the insulating body 17 and S1' between the sleeves 125a, 125b and the insulating body 117 are maintained at nominal values, e.g., 0.2 mm. The nominal clearance gaps S1, S1' allow for elastic movement of the contact sleeves 25a, 25b and the insulating body according to required length compensation, as described with reference to FIG. 3D. However, the clearance gap S1 does not change with the occurrence of relative movement or mechanical force between the sleeves 25a, 25b and the insulating body 17.

[0133] In FIG. 3B, because contacts 113a', 113b' have a minimum length within manufacturing tolerances, the outer shell 7 is threaded and mated further in the mating direction x, requiring the user to thread the outer shell 7 further until electrical contact pairs 13a'-113a', 13b'-113b' abut. Again, abutment of the mating shell end faces 14, 114 does not occur. There is still a gap D2 between the bottoming of shell 105 on inner shell 7 of connector 1, but this gap D2 is smaller than gap D1, e.g., 0.1 mm. As explained above, because contact pairs 13a'-113a', 13b'-113b' abut evenly, clearance gaps S1, S1' remain unchanged.

[0134] In FIG. 3C, contacts 113a'', 113b'' have maximum lengths within manufacturing tolerances, so bottoming out occurs earlier, and the mating and coupling of the outer shell 7 by threading progresses less along the mating direction x. Therefore, the gap D3 between the bottoming out of the outer shell 7 in shell 105 of the second connector 101 is larger than the gap D1, here, for example, 0.9 mm. Because the contact pairs bottom out evenly, the clearance gaps S1, S1' remain unchanged. Again, bottoming out occurs between the end faces of electrical contacts 13a''-113a'', 13b''-113b'', but not in shells 5, 7, 105.

[0135] In FIG. 3D, electrical contact 113a''' is shorter than electrical contact 113b'''. Therefore, if contacts 13a''' and 113a''' are not bottomed out, i.e., not held in abutting contact, vibration can cause accumulated fretting corrosion. Connector 1 according to this embodiment of the invention addresses this risk by providing pivoting lever 49, which shifts the positions of contacts 13a''', 13b''' until all contact pairs 13a'''-113a''', 13b'''-113b''' are bottomed out.

[0136] In particular, when the longer male mating contact 113b''' abuts the female electrical contact 13b''', further mating progression due to continued screwing of the outer shell 7 onto the shell 105 transmits a force to the lever 49. In particular, a force is exerted by the pusher element 47 on the fulcrum 51 such that the lever 49 pivots about the axis z until the shorter contact pair 13a'''-113a''' bottoms out as well. This is possible because the contact 13a and its sleeve 25a can move within the housing 3.

[0137] Any misalignment of the contacts is accommodated by the clearance between the insulating bodies 17, 117 and the contact sleeves 25a, 25b. Thus, in the contact configuration of Figure 3D, pivoting the lever 49 increases the gaps S2, S2' between the "long" contact pair 13b'''-113b''' and the insulating bodies 17, 117. For example, when the lever 49 tilts toward the "short" contact pair 13a''', 113a''', causing the relative position of the contacts 13a''', 13b''' to shift with respect to the housing 3, the gaps S2, S2' increase from 0.2 mm to 0.4 mm.

[0138] At the same time, the gaps S3, S3' between the shorter contact 113a''' and its counterpart contact 13a''' and the insulating body 17, 117 are reduced, for example, from 0.2 mm to 0.0 mm. Thus, 0.4 mm of margin is wasted on the side of the "short" contact pair. With the increased size of gaps S2, S2' compared to gaps S1, S1', the 0.8 mm difference in length between contacts 113a''' and 113b''' is absorbed without surfaces 14, 114 abutting. In other words, the difference in contact length is compensated for by pivot lever 49, and contacts 13a''', 13b''' are displaced relative to housing 3, and in particular relative to end surface 14 of inner shell 5, so that contact pairs 13a'''-113a''', 13b'''-113b''' fully bottom out regardless of the difference in their contact lengths.

[0139] Thus, the present invention provides a high-power connection that is resistant to fretting corrosion under vibration loads. The required level of resilience can be achieved without the need to resort to fixed lug connections, as known from the prior art. This allows for faster and easier installation and maintenance, as well as greater safety since the conductors under high power are no longer exposed. Furthermore, the total mass of the connection is smaller and the contact resistance is lower, resulting in higher power performance. Furthermore, higher voltages can be utilized, ensuring better electromagnetic compatibility with other on-board equipment. Finally, an improved service life can be realized.

[0140] In further embodiments of the present invention, the number of electrical contacts carried by the electrical connector can be increased, for example, to three. FIG. 4 illustrates a lever 49' for an electrical connector according to an alternative embodiment of the present invention, configured to accommodate a third contact sleeve, such as a third sleeve in addition to contact sleeves 25a and 25b. Lever 49' includes a central protruding bulge 69 extending from a top surface 67' and three semi-cylindrical cutouts 61a', 61b', and 61c' evenly distributed around the bulge 69 to achieve three-fold rotational symmetry. Semi-cylindrical cutouts 61a', 61b', and 61c' are configured to accommodate the three contact sleeves. Lever 49' further includes a respective load tip 65e adjacent each of semi-cylindrical cutouts 61a', 61b', and 61c'.

[0141] In this configuration, the lever does not pivot two-dimensionally in the xy plane about axis z, but rather pivots freely three-dimensionally about any axis, thereby accommodating variations in the lengths of the corresponding electrical contacts relative to each other and the housing. This is possible because the three electrical contacts of different lengths can define a plane between the three center points of their distal end faces. To accommodate the three-dimensional pivotal movement of the lever and the three corresponding contact sleeves, the corresponding pusher element may be formed, for example, in a Y-shape in the yz plane, instead of a cross beam as shown in FIG. 2B.

[0142] To accommodate even more contacts, further alternative embodiments may provide additional levers stacked beneath lever 49 such that bulges on the additional levers are positioned beneath load tips 65a-65d of lever 49. In such a "cascading arrangement," the self-aligning nature of the electrical contacts in the connector may be maintained.

[0143] The embodiments described above with respect to the first aspect of the invention, and the described embodiments of the method according to the invention, relate to the abutment of distal end faces of electrical contacts, in particular mating distal end faces 22a-122a, 22b-122b, and E22b, E122b. In light of the description of Figure 9, it will be clear that the invention can be implemented with any mating end face and is not limited to the abutment of distal end faces of electrical contacts.

[0144] An embodiment of the second aspect of the present invention will now be described with reference to Figure 5. Figure 5 shows a connector assembly 1000 comprising a first electrical connector 501 and a second electrical connector 601 mated along a mating axis AX. In Figure 5, the connectors 501, 601 are in a fully mated state.

[0145] The connector assembly 1000 does not include, use, or provide for a lug connection and is therefore lug-free. Furthermore, the connector assembly 1000 is designed to have insulating and conductive properties for high power applications using currents of 50 A or more, particularly for currents between 50 A and 1000 A.

[0146] The first connector 501 includes a first housing 503 that defines an interior connector space 545 , and the second connector 601 includes a second housing 603 that defines a second interior connector space 645 .

[0147] The first electrical connector 501 includes two first electrical contacts 513a, 513b housed in an internal connector space 545. The contacts 513a, 513b mate with corresponding electrical contacts 613a, 613b of a second connector. In the embodiment of FIG. 5, the connector 601 is a mobile connector and has female electrical contacts 613a, 613b. The connector 601 is configured to be screwed into a fixed connector 501 having male electrical contacts 513a, 513b. According to a variant, the arrangement could be reversed so that the male contacts are with the mobile connector and the female contacts are with the fixed connector. In this embodiment, the first electrical connector 501 and the second electrical connector 601 have a thread feature on the surface of the housing shell, as already described for the connectors 1, 101 described in connection with the first aspect. In particular, the first connector 501 has external threads 535 and the second connector 601 has internal threads 635. As mentioned above, other types of connection and fastening means can also be used.

[0148] The distal end faces 522a, 522b of each of the first electrical contacts 513a, 513b abut against the mating side faces 622a, 622b of the receptacles 615a, 615b of the mating corresponding electrical contacts 613a, 613b, respectively. Additionally, the distal end faces 522a, 522b also abut against the facing surfaces 523, 623 of the housings 503, 603. The distal end faces 522a, 522b are front end faces of the electrical contacts that are configured to provide electrical contact and power transmission, particularly through planar contact. For example, the planar contact is perpendicular to the mating direction x.

[0149] In this example, contact 513a is longer than contact 513b by a length difference within manufacturing tolerances, e.g., 0.5 mm. Thus, this length difference, although not visible in FIG. 5, is present and poses a risk of fretting corrosion under vibration loads. Thus, during mating and coupling of connector 601 with connector 501 by threading as described in the previous embodiment, contact surfaces 522a and 622a abut first.

[0150] As mating and coupling of the housings 503, 603 continues after the first abutment of the contact surfaces 522a, 622a, the housing 501 tilts relative to the housing 503 about the mating axis AX towards the side of the shorter contact 513b.

[0151] This tilt is shown in an exaggerated manner in Figure 5 by the angle α. The tilt at angle α is made possible by the thread clearance between the first thread 535 of the first electrical connector 501 and the second thread 635 of the second connector 601, and is mechanically fixed. Due to the tilt at angle α, the abutment of the mutually facing surfaces 523, 623 of the housings 503, 603 is released on the sides where the housing 503 tilts away, and the surfaces 523, 623 only partially abut.

[0152] The tilt of the first housing 503 causes the shorter electrical contacts 513b to move forward until their distal end faces 522b abut the mating side faces 622b of their corresponding contact receptacles 615a. In particular, the tilt of the first housing 503 allows the second abutment at faces 522b, 622b to occur while also maintaining faces 522a, 622a in abutting contact.

[0153] Thus, the abutment of all the electrical contact pairs 513a-613a, 513b-613b is fixed by the inclined positioning of the first housing 503 relative to the mating second housing 603 with respect to the mating axis AX.

[0154] The thread clearance in the threads 535, 635 allows the first housing 603 to tilt relative to the second housing 503 along the mating axis AX without damaging the housings 503, 603 or jeopardizing the mechanical integrity of the connection. In particular, the thread clearance limits the tilt to a predetermined maximum angular displacement depending on the thread clearance of the first thread 535 and the second thread 635.

[0155] The lugless assembly 1000 allows variations in electrical contact length within manufacturing tolerances to be compensated for by tilting the first connector housing 503 relative to the second connector housing 603 .

[0156] Another embodiment of the second aspect of the present invention will now be described with reference to Figure 6. Figure 6 provides a perspective view of a first connector 701 and a second connector 801 of a lugless electrical connector assembly according to the present invention, suitable for high power applications using currents of 50 A or more. The first connector 701 is an electrical plug connector and the second connector 801 is an electrical receptacle connector. The first connector 701 and the second connector 801 are configured to mate but are not yet assembled together in the view of Figure 6.

[0157] The first electrical connector 701 has a first housing 703, and the second electrical connector 801 has a mating second housing 803. In this embodiment, the second connector 801 is a fixed connector, and the first connector 701 is a movable connector.

[0158] The housing 703 of the first electrical connector 701 and the housing 803 of the second electrical connector 801 have a rectangular shape in the yz plane perpendicular to the mating axis AX. In contrast to the connectors 501, 701 described above, the first housing 703 comprises a threaded plug 735 and the second housing 803 comprises a threaded receptacle 835. Mating and coupling thus occurs by screwing in a threaded central plug, rather than by screwing in outer shells as described for example with respect to connectors 1, 101.

[0159] The first electrical connector further comprises four male electrical contacts 713 contained within the housing 703 and configured to mate with mating female electrical contacts. In particular, the distal end faces 722 are configured to abut against respective mating sides of the corresponding electrical contacts.

[0160] A threaded plug 735 and a threaded receptacle 835 extend centrally through the respective housings 703, 803, with the plug 735 configured to mate with the receptacle 735 during mating. In particular, to mate the connectors 701, 801, the housings 703, 803 are mated such that the plug 735 is inserted into the receptacle until the threads interlock. The threaded plug 735 is then manually screwed into the receptacle 835.

[0161] The contacts 713 are distributed two by two on tilting elements 734 housed in the housing 703. In particular, the tilting elements 734 are connected to hinges 736 so as to be tiltable about respective tilt axes parallel to a direction z perpendicular to the mating direction x, thereby being tiltably disposed on the housing 703. For example, the tilting elements 734 can be tilted around the hinges 736 by exemplary angles α′ and α″ on the housing 703.

[0162] The tiltable arrangement allows for compensation for differences in contact lengths, as previously described with respect to previous arrangements. That is, once bottoming out of a first contact occurs and mating proceeds, e.g., by threading plug 735 into receptacle 835, the tiltable arrangement about hinge 736 allows tilting element 734 to tilt until a second bottoming out is achieved. Thus, all contact pairs are bottomed out before housings 703, 803 are bottomed out, reducing or eliminating the risk of fretting corrosion.

[0163] In a further alternative embodiment of the second aspect, the first electrical connector may be an electrical connector described with respect to the first aspect of the invention, such as connector 101 of FIG. 1B. In another alternative embodiment, the second electrical connector may be a mating connector described with respect to the first aspect of the invention, particularly FIG. 1A. In a further alternative embodiment, both the first connector and the second connector may be connectors 1 and 101 of the first aspect as shown in FIG. 1C.

[0164] Thus, the present invention provides a high-power connector assembly that is resistant to fretting corrosion under vibration loads. The required resilience levels can be achieved without the need for fixed lug connections, as known from the prior art. This allows for faster and easier installation and maintenance, and also provides greater safety since the conductors under high power are not exposed. Furthermore, the total mass of the connection is smaller and the contact resistance is lower, resulting in higher power performance. Furthermore, higher voltages can be utilized, ensuring better electromagnetic compatibility with other vehicle equipment. Finally, an improved lifespan can be realized.

[0165] The embodiments described above with respect to the second aspect of the present invention relate to the abutment of distal end faces of electrical contacts, particularly mating distal end faces 522a-622a, 522b-622b and 722. In light of the description of Figure 9, it will be clear that the present invention can be implemented with any mating end face and is not limited to the abutment of distal end faces of electrical contacts.

[0166] An embodiment of a lugless connector assembly according to the third aspect of the present invention will now be described with reference to Figures 7A and 7B.

[0167] 7A shows a perspective view of a first electrical connector 1001 for a lug-less connector assembly according to one embodiment of the third aspect of the present invention. The first electrical connector 1001 shares many structural elements with the electrical connector 1 shown in FIG. 1A for the first embodiment of the present invention.

[0168] In particular, the first electrical connector 1001 is configured to mate with a mating second electrical connector, such as the second electrical connector 1101 shown in FIG. 7B , in a mating direction x parallel to the mating axis AX. The electrical connector 1001 is also a movable connector, also referred to as a plug connector, that is manually mated with a fixed or non-movable mating second connector, also referred to as a receptacle. For example, the electrical connector 1001 is suitable for establishing a power transmission connection for a power cable in an electric vehicle, such as an electric aircraft.

[0169] The electrical connector 1001 also comprises a housing 1003 including an inner shell 1005 having a shell end face 1014 and surrounded by an outer shell 1007 having an outermost surface 1009 and a textured surface portion 1011. The shell end face 1014 is the farthest or outermost surface or ridge of the connector 1001 in the direction of mating with a mating connector, i.e., in the mating direction x.

[0170] The electrical connector 1001 further comprises a boundary thermoplastic insulating mass 1017 having a protrusion 1019, a centering key 1037 on the outer surface of the inner shell 1005, a serrated peripheral ridge 1027 on the outer shell 1007, and a metal band 1029 between the shells 1005, 1007. The connector 1001 also comprises a threaded surface 1035. The threaded surface 1035 is an internal thread that provides a mechanical coupling for coupling the connector 1001 to a mating second electrical connector. In variations of the invention, other mechanical coupling devices may be used, such as a friction fit or a clip-on device.

[0171] However, in contrast to the other embodiments, the electrical connector 1001 includes only one electrical socket contact 1013 disposed inside an inner shell 1005 that extends parallel to the mating axis AX inside the housing 1003. The contact 1013 includes a receptacle 1015 that is configured to receive a male contact of a mating second connector. The receptacle 1015 of the contact 1013 mates with an opening 1021 in an insulating body 1017. The receptacle 1015 includes an end face 1022 that provides the primary power contact surface of the electrical socket contact 1013.

[0172] The electrical socket contacts 1013 are held in hollow contact sleeves 1025 that are used to receive and lock the electrical contacts 1013 into the housing 1003. In addition, the connector 1001 includes a safety pin 1031 that is movable between a secure position and an unsecured position. In the view of Figure 7A, the electrical contacts 1013 and contact sleeve 1025 are fully locked into the housing 1003, as shown by the safety pin 1031 in the secure position where the pin 1031 is fully retracted inside the housing 1003. For example, if either the sleeve 1025 or the contact 1013 is improperly assembled in the housing 1003, the safety pin 1031 moves to an unsecured position in which the pin 1031 protrudes from the housing 1003 in the mating direction x of a corresponding mating connector, such as the second electrical connector 1101. In the unsecured position, the protruding safety pin 1031 prevents mating of the connector 1001 with the mating electrical connector.

[0173] Figure 7B shows a cross-sectional view of a lug-less connector assembly 2000 including the connector 1001 of Figure 7A and a second electrical connector 1101. The view in Figure 7B is for a single-contact lug-less connector assembly and corresponds to the views shown in Figures 2A and 5 for a dual-contact connector assembly. The internal configuration of connectors 1001, 1101 matches that of the connectors described with respect to previous embodiments, but has been simplified to include only a single electrical contact.

[0174] In particular, the connector 1001 mates with the second electrical connector 1101 by threading the internal threads 1035 of the first housing 1003 together with plug threads 1135 formed on the shell 1105 of the second housing 1103 of the second electrical connector 1101. In alternative embodiments, the connector 1001 and the second electrical connector 1101 may be coupled by mechanical coupling means other than threads 1035, 1135. For example, other friction-fit and / or form-fit mechanical coupling means for coupling the connectors 1001, 1101 may be used, such as a snap-fit ​​clip fastening device.

[0175] As shown in FIG. 7B , the first housing 1003 of the first electrical connector 1001 defines an interior connector space 1045 and houses contact sleeves 1025 that hold the electrical contacts 1013. Correspondingly, the second housing 1103 houses corresponding electrical contacts 1113. The second housing 1103 also houses an insulating body 1117, e.g., an elastomer, that mates with the insulating body 1017 of the first connector 1001. A secondary insulating layer 1118 in the second housing 1103 provides additional contact mounting and insulating properties. An O-ring 1144 inside the shell 1105 of the second connector 1101 provides an additional seal for mating with the first connector 1001. As described with respect to the first embodiment, a friction ring 1042 is circumferentially disposed around the inner shell 1005 so as to make partial frictional contact with the outer shell 1007 and fix the rotational state of the outer shell 1007 relative to the inner shell 1005.

[0176] Since the contacts 1013 are electrical sockets or female contacts, the corresponding electrical contacts 1113 are male contacts. The corresponding electrical contacts 1113 are removably form-fit into contact sleeves 1125, which in turn are removably form-fit into the housing 1101, as is known from the embodiment of the first aspect described with reference to Figures 1A-2D.

[0177] 7B shows the assembly of the first electrical connector 1001 and the second electrical connector 1101 in a fully mated and coupled state, with the distal end face 1022 of the first electrical contact 1013 abutting the corresponding mating male distal end face 1122 of the corresponding electrical contact 1113. The distal end faces 1022, 1122 are front end faces of the electrical contacts configured for electrical contact and power transmission, particularly through planar contact. For example, the planar contact is perpendicular to the mating direction x. For example, in the case of a female electrical contact such as contact 1113, the distal end face is the bottom surface of the contact receptacle 1115.

[0178] In particular, the distal end faces 1022 and 1122 abut, but the first housing 1003 and second housing 1103, which mate via threads 1035, 1135, do not bottom out. This can be achieved, for example, by adjusting the nominal lengths of the contacts 1013, 1113 and their attachment to the housings 1003, 1103 so that the shell end face 1014 of the first housing 1003 of the first electrical connector 1001 does not abut the corresponding shell end face 1114 of the second housing 1103 of the second electrical connector 1101.

[0179] Instead, the contact distal end faces 1022, 1122 bottom out against one another, but the shell end faces 1014, 1114 are separated by a distance D11. Similarly, the inner shell 1005 of the housing 1003 of the first electrical connector 1001 does not bottom out against the housing 1103 of the second electrical connector 1101 in the mating direction x, but remains separated by a distance D12. The alternative leading ends of the housings 1003, 1103 in the mating direction x are also still separated by a distance D12, as shown in FIG. 7B . Thus, similar to the previous embodiment, connector bottoming is shifted from the housings 1003, 1103 to the contacts 1013, 1113, particularly the contacting end faces 1022 and distal end faces 1122. The bottomed contacts 1013, 1113 are therefore less susceptible to vibration-induced relative movement, reducing or eliminating fretting corrosion.

[0180] 7B also shows anti-separation device 1024. Anti-separation device 1024 is positioned in a portion of inner shell 1005 of housing 1003 such that spring-activated ball locks 1024a of anti-separation device 1024 abut against outer shell 1007. This statically maintains the position of outer shell 1007 relative to inner shell 1005 in a given rotational state, particularly when the balls enter corresponding recesses in outer shell 1007, thereby preventing undesired separation.

[0181] The embodiments described above with respect to the third aspect of the invention relate to abutting distal end faces of electrical contacts, particularly mating distal end faces 1022-1122. In light of the description of Figure 9, it will be clear that the invention can be implemented with any mating end face and is not limited to abutting distal end faces of electrical contacts.

[0182] An apparatus and method for removing contact sleeve 125 from electrical connector 101 will now be described with reference to Figure 8. The inventive concept of removing contact sleeve 125 from an electrical connector may be implemented with any type of electrical connector, particularly electrical connectors for high power vehicle applications, independent of the connectors described above with reference to Figures 1-7.

[0183] Figure 8 shows a partial cutaway view of the second connector 101 described above according to the first embodiment of the present invention. The second connector 101 has already been described in detail with respect to Figures 1B, 1C, 2A, 2D and 3A-3D, and in particular with respect to Figure 1B. Features having reference numbers already used will not be described in detail again, and reference is made to the above description thereof.

[0184] FIG. 8 corresponds to an off-center cross-section of the connector 101, ie a cross-section displaced laterally from the mating axis Ax, which corresponds to the central axis of the connector 101, in order to visualize the internal components.

[0185] FIG. 8 also shows the external sleeve removal tool T1 in addition to the second connector 101. The sleeve removal tool T1 comprises a first cylindrical portion T3 and a second cylindrical portion T5, which are formed together as a single piece. The second portion T5 extends coaxially from the first portion T3. The first portion T3 has a larger diameter than the second portion T5, specifically two to four times larger. To facilitate manual grasping and manipulation of the tool T1, the diameter of the second portion T5 is adapted to be inserted into a corresponding opening 128b located in the second connector 101.

[0186] In an alternative embodiment, the enlarged second portion T5 may be, for example, key-shaped or rectangular instead of cylindrical, to make it easier to grip the second portion T5.

[0187] The opening 128b is located adjacent to the position of the contact sleeve 125b, particularly in the rear cover 143. The opening 128b has a diameter that is more than five times, particularly more than ten times, smaller than the diameter of the contact sleeve 125b.

[0188] The sleeve removal tool T1 is required to enable removal of the electrical contact sleeve 125b for the electrical contacts in the electrical connector 101. The sleeve removal tool T1 is insertable into the corresponding opening 128b to displace the safety pin 131b as described in one of the embodiments of the present disclosure, e.g., FIG. 1B.

[0189] The pin 131b is movable between a safe position and an unsafe position, and in the unsafe position, the safety pin protrudes from the insulating body 117 outside the connector 101, as shown in FIG. 1C, preventing the connector 101 from mating with the electrical connector 1.

[0190] 8, safety pin 131b has been moved to a secure position in which safety pin 131b is fully retracted inside connector 101. Safety pin 131b extends throughout second connector 101, particularly through cutout spaces in elastomeric insulating body 117, secondary thermoplastic insulating body 118 and rear cover 143. As already explained above with respect to FIGS. 1A-2D, because safety pin 131b is retracted, it does not protrude from connector 101 and therefore no longer prevents mating and / or coupling of connector 101 with a mating electrical connector 1.

[0191] The safety pin 131b has an L-shaped body, with a long arm 132a of the body extending along the mating axis Ax through the second connector 101. The short arm 132b is arranged perpendicular to the mating direction x on the side of the connector 101 facing the mating direction x. A tip 132c of the short arm 132b extends into the space formed by the opening 128b. Thus, the tip 132c of the safety pin 131b can be fitted into the opening 128b by inserting an object, in particular the second part T5 of the instrument T1.

[0192] 1A to 3D, the second connector 101 includes a spring arrangement. In particular, as shown in Fig. 8, the connector 101 includes a spring element 134 housed inside a spring space 136. In this embodiment, the spring element 134 is a helical coil spring that is arranged parallel to the mating axis Ax, i.e., such that the restoring spring force FS is oriented parallel to the mating axis Ax.

[0193] A first end 134a of the spring element 134 abuts the connector 101, in particular the secondary thermoplastic insulating body 117. A second end 134b of the spring element 134 abuts the tip 132c of the short arm 132b of the safety pin 131b. In this spring arrangement, the spring element 134 is preloaded such that a spring force FS acts on the tip 132c of the safety pin 131b, pressing it against the cover 149 of the connector 101 in the mating direction x along the mating axis Ax.

[0194] The retracted safety pin 131b prevents the sleeve 125b from rotating about its central axis A 125B, for example due to undesired manual or environmental action. The prevention of rotation of the sleeve 125b about its axis A 125B in the safety position is obtained by a shear protrusion 73b, the structure and function of which is described in detail above with reference to FIG. 2C, but is not visible in FIG. 8. The shear protrusion 73b protrudes from the outward-facing surface 38b, and therefore, when the shear protrusion 73b abuts the retracted safety pin 131b, rotation of the sleeve 125b about its axis A 125B is prevented.

[0195] The second portion T5 of the sleeve removal tool T1 is inserted into the opening 128b to remove the contact sleeve 125b, e.g., to inspect, maintain, or replace the installed electrical contacts 113b. As the removal tool T1 is forced into the opening 128b with at least a predetermined force FT, the restoring spring force FS can be overcome and the safety pin 131b is displaced along the mating axis from the secure position to an unsecure position in which the safety pin 131b protrudes outward from the interface 123 from the second connector 101.

[0196] In the unsecured position, the contact sleeve 125b can be rotated about its axis A 125b so that the shearing projections 73b are moved from their positions in the recesses inside the connector and are no longer blocked by the long arms 132a of the safety pin 131b. In particular, the contact sleeve 125b can be rotated to a position where the shearing projections 73b can be passed through corresponding guide spaces 174a, 174b in the connector 101, thereby allowing the contact sleeve 125b to be withdrawn from the connector 101.

[0197] Conversely, in the non-secure position, the contact sleeve 125b does not rotate about its axis A 125b into a properly locked position, and the shear projection 73b therefore does not rotate with the contact sleeve 125b into its final position, but remains at least partially in the guide space 74b, preventing the spring-actuated upward movement of the outwardly extending safety pin 131b to retract back into the connector 101.

[0198] In this manner, the location of the safety pin 131b prevents mating of the connector 101 with the mating connector 1 unless the contact sleeve 125b is properly positioned in the desired rotational position about its central axis A125B.

[0199] The same mechanism can be envisaged for the second contact sleeve 125a, which is also removably disposed.

[0200] A corresponding mechanism, in particular a corresponding spring and through-hole, may be arranged on the other side, ie the side of the connector 101 that is not visible in FIG. 8, with respect to the other safety pin 31a and contact sleeve 25a.

[0201] The methods and structural features described above with respect to the second connector 101 of the first aspect of the invention may be applied equally to any other connector, in particular to the connector 1 according to the invention.

[0202] Figure 9 shows a comparative view of alternative pairs of electrical contacts. In particular, Figure 9 shows a first pair of electrical contacts A13a-A13b and an alternative second pair of electrical contacts B13a-B13b side-by-side, corresponding to electrical contact pairs 13a-13b, 113a-113b, 513a-513b, 613a-613b, and 1013-1113 as described above.

[0203] The electrical contact A13a is a plug-type electrical contact, and the other electrical contact A13b is a receptacle-type electrical contact. In Fig. 9, the mating electrical contacts A13a and A13b are bottomed at their respective end faces A22a and A22b. Here, the distal end face A22a abuts against the bottom of the corresponding female receptacle.

[0204] However, the present invention is not limited to this type of connector. Electrical contacts B13a and B13b in Figure 9 show an alternative example. In this alternative example, electrical contact B13b corresponds to electrical contact A13b and is a receptacle-type electrical contact, and electrical contact B13a is also a plug-type electrical contact.

[0205] The plug B13a_p of the contact B13a has a central protruding portion B13a_c surrounded by a recessed portion B13a_s, which does not extend to the protruding portion B13a_c in the mating direction x. Here, the recessed portion B13a_s abuts and bottoms out against the distal end face B22b of the receptacle shell B13b_s of the receptacle contact B13b. Thus, in this embodiment, the distal end face B22b of the electrical contact B13b abuts against the terminal end face B22a of the recessed portion B22_s of the electrical contact B13a.

[0206] In the example of Figure 9, faces A22a, A22b and B22a are planar and perpendicular to the mating direction x, although the mating end faces of the electrical contacts may also be inclined with respect to the mating axis x.

[0207] While each aspect of the invention has been described with reference to specific examples, the invention is not limited to the described embodiments, and numerous modifications to the disclosed embodiments may be made without departing from the scope of the invention. Individual features included in the various embodiments may be freely combined with one another to obtain further embodiments or examples in accordance with the invention. [Explanation of symbols]

[0208] 1 connector 3. Housing 5 Inner shell 7 Outer Shell 9 Outermost surface 11. Outermost uneven surface 13a, 13b Electrical socket contacts 14 Connector outer shell end face 15a, 15b Electrical socket contact receptacle 17 Insulating objects 19a, 19b Protrusions of insulating objects 21a, 21b Opening of protrusion of insulating object 22a, 22b Female mating side 23 Boundary of insulating objects 25a, 25b contact sleeve 26a, 26b Internal cavity of sleeve 27 Serrated ridge 29 Metal Band 31a, 31b safety pin 33 Intershell space 35 Thread surface 37 Centering key 38a, 38b Outward facing surfaces of contact sleeve 39b Wiring Receptacle 41a, 41b Triple Barrier Grommets 42 Friction Ring 43 Rear cover 45 internal connector space 47 Pusher Element 49, 49' lever 51 Fulcrum 53 Pusher element cross beam 55a, 55b Lateral arms of pusher element 57a, 57b Outer side of horizontal arm 59a, 59b Recesses in the horizontal arms 61a, 61b, 61a', 61b', 61c' semi-cylindrical cutout section 63a~63d Lever arm 64a, 64b, 64c Peripheral cutout of semi-cylindrical cutout 65a~65d Load tip 65e Load tip of lever in three contact embodiment 67, 67' Top 69 Bulge 71a, 71b Shear section 73a, 73b Shear protrusions 75a, 75b Load surface 77a Inner ledge of sleeve 79a Protrusion of contact 13a 81a, 81b Through holes to wiring receptacles 83a, 83b recesses 101 Second Connector 103 Second connector housing 105 Second connector shell 107 Base Plate 109 Outermost surface of the shell of the second connector 111 Through hole 113a, 113b corresponding male electrical contacts 113a', 113b' corresponding male electrical contacts having a minimum length 113a'', 113b'' corresponding male electrical contacts having maximum lengths 113a''', 113b''' corresponding male electrical contacts having unequal lengths 114 Mating end face of shell of second connector 117 Second connector insulating material 118 Secondary insulation layer 119a, 119b hollow 121a, 121b cavity opening 122a, 122b distal end face 123 Opposite boundary surface 125a, 125b contact sleeve 127 Serrated ridge 128b Through hole 129 Surface of insulating object 131a, 131b safety pin 132a Long Arm 132b Short arm of safety pin 132c Tip of the short arm of a safety pin 134 Spring Elements 134a, 134b: First end and second end of spring element 136 Spring Space 133 Annular Intermediate Space 135 Thread surface of second connector 137 Centering recess 141a, 141b Triple Barrier Grommet 143 Back cover 145 Interior Space 147 Pusher Element 149 Lever 174a, 174b Guide spaces for shear projections 200 Connector Assembly 501 first electrical connector 503 First Housing 513a, 513b First electrical contacts 522a, 522b Distal end faces of first electrical contacts 523 Interface of First Electrical Connector 535 Male thread of first connector 601 second electrical connector 603 Second Housing 613a, 613b Second electrical contacts 615a, 615b Second electrical contact receptacle 622a, 622b Mating sides of second electrical contact 623 Interface of Second Electrical Connector 635 Second connector female thread 701 Electrical Plug Connector 703 Housing 713 Electrical Contacts 722 Male mating side of contact 735 Threaded Plug 736 Hinges for tilting elements 801 Electrical Receptacle Connector Housing for 803 connector 835 Threaded Receptacle 1001 A first electrical connector according to an embodiment of the third aspect of the present invention 1003 First Housing 1005 Inner shell of first housing 1007 Outer shell of first housing 1009 Outermost surface of outer shell 1011 Outermost uneven surface 1013 Electrical Socket Contact 1014 Shell end face 1015 Electrical Socket Contact Receptacle 1017 Thermoplastic insulating materials 1019 Protrusions of insulating objects 1022 Distal end face of electrical contact 1025 First Contact Sleeve 1027 Sawtooth Ridge 1029 Metal Band 1031 First Safety Pin 1035 thread surface 1037 Centering key 1042 Friction Ring 1045 Internal Connector Space 1101 A second electrical connector according to an embodiment of the third aspect of the present invention 1103 Second Housing 1105 Second housing shell 1113 Corresponding electrical contacts 1114 Shell end face 1117 Elastomer insulating material 1118 Thermoplastic secondary insulation layer 1122 Distal end face 1024 Separation prevention device 1024a Ball lock for anti-separation device 1125 Second Contact Sleeve 1135 Thread surface 1144 Sealing O-ring 2000 Lugless Connector Assembly According to an Embodiment of the Third Aspect of the Invention x Mating direction y, z orthogonal plane axes AX mating shaft A125B Central axis of contact sleeve 125b A13a, A13b Mating pairs of conventional electrical contacts A22a, A22b Counterpart end surface B13a, B13b Alternative mating pairs of electrical contacts B13a_c Central protrusion of electrical contact B13a_p Electrical Contact Plug B13a_s Retracted portion of electrical contact B13b_s Electrical Contact Receptacle Shell B22a, B22b Mating end faces of electrical contacts C1 reaction force D1, D2, D3, D4 Housing clearance for different contact length configurations D11, D12 Housing gaps in an embodiment according to the third aspect of the present invention E1, E101 connectors for connection methods Contacts in E13a, E13b, E113a, E113b connection methods E22b, E122b electrical contact mating side E149 Lever F Mating Force FS spring force FT Instrument Power S1, S1' Clearance between insulating body and sleeve under nominal conditions S2, S2' Longer side clearance under uneven conditions S3, S3' Short side clearance under uneven conditions T1 Sleeve Removal Instrument T3 First part of sleeve removal tool Second part of the T5 sleeve removal tool N nominal length α, α', α'' Tilt angle Δ Difference in length

Claims

1. An electrical connector (1) configured to mate with a second electrical connector (101) in a mating direction (x) parallel to a mating axis (AX), comprising: a housing (3) defining an interior connector space (45) and configured to mate with a mating housing (103) of the second electrical connector (101); At least two electrical contacts (13a, 13b) received in the internal connector space (45) and configured to mate with corresponding electrical contacts (113a, 113b) of the second electrical connector (101); In an electrical connector (1), a lever (49) housed in the internal connector space (45) such that mechanical contact between the housing (3) and the lever (49) establishes a fulcrum (51) of the lever (49); the fulcrum (51) is positioned so as to be disposed between the at least two electrical contacts (13a, 13b); The lever (49) is further arranged and configured such that pivoting of the lever (49) moves the positions of the at least two electrical contacts (13a, 13b) relative to the housing (3). An electrical connector (1).

2. The housing (3) further comprises a shell (5) and a pusher element (47), the pusher element (47) is disposed in the interior connector space (45) and is rigidly attached or form-fitted to the shell (5) of the housing (3); The pusher element (47) provides mechanical contact between the housing (3) and the lever (49) at the fulcrum (51). An electrical connector (1) according to claim 1.

3. The lever (49) is configured such that pivoting of the lever (49) causes the positions of the at least two electrical contacts (13a, 13b) to move parallel to the mating axis (AX) relative to the housing (3). An electrical connector (1) according to claim 1 or 2.

4. The lever (49) has a protrusion (69) that protrudes from a surface (67) of the lever (49) in a direction opposite to the mating direction (x), The tip of the protrusion (69) is a mechanical contact point with the housing (3) that establishes a fulcrum (51). An electrical connector (1) according to claim 1 or 2.

5. Each electrical contact (13a, 13b) is held in, or form-fit and / or friction-fit with, a corresponding contact sleeve (25a, 25b); Each contact sleeve (25a, 25b) has at least one shear portion (71a, 71b) on its outer side; the shear portions (71a, 71b) are configured to establish mechanical contact with the lever (49); An electrical connector (1) according to claim 1 or 2.

6. The shearing portions (71a, 71b) include protrusions (73a, 73b) having load surfaces (75a, 75b) facing in the opposite direction to the mating direction (x), The load surfaces (75a, 75b) are configured to receive a mechanical load from the lever (49). An electrical connector (1) according to claim 5.

7. Each of the load surfaces (75a, 75b) of each of the contact sleeves (25a, 25b) abuts against a corresponding load tip (65a-65d) of the lever (49). An electrical connector (1) according to claim 6.

8. the load tips (65a-65d) of the lever (49) rest freely on the respective load surfaces (75a, 75b) of the contact sleeves (25a, 25b), thereby allowing sliding of the load tips (65a, 65b) on the load surfaces (75a, 75b); An electrical connector (1) according to claim 7.

9. further comprising at least one safety pin (31a, 31b) movable between a safety position and an unsafe position; In the non-safety position, the safety pins (31a, 31b) are configured to protrude from the housing (3) in the mating direction (x) to block the second electrical connector (101), thereby preventing mating of the electrical connector (1) with the second electrical connector (101). An electrical connector (1) according to claim 1 or 2.

10. Further comprising one corresponding safety pin (31a, 31b) for each contact sleeve (25a, 25b); Each safety pin (31 a, 31 b) is movable between a respective safety position and a respective non-safety position; In the non-safety position, each safety pin (31a, 31b) is configured to protrude from the housing (3) in the mating direction (x) to block the second electrical connector (101), thereby preventing mating of the electrical connector (1) with the second electrical connector (101). An electrical connector (1) according to claim 5.

11. An electrical connector assembly (200) comprising the electrical connector (1) according to claim 1 or 2 and a second electrical connector (101), The second electrical connector (101) comprises a mating housing (103) configured to mate with the housing (3) of the electrical connector (1) and corresponding electrical contacts (113a, 113b) configured to mate with the electrical contacts (13a, 13b) of the electrical connector (1); The lever (49) pivots about the fulcrum (51) so that each electrical contact (13a, 13b) bottoms out against a corresponding electrical contact (113a, 113b). An electrical connector assembly (200).

12. 3. A lugless electrical connector assembly comprising a first electrical connector (501) according to claim 1 or 2 mating with a second electrical connector (601) along a mating axis, The first electrical connector (501) comprises a first housing (503) defining an internal connector space (545) that mates with a mating second housing (603) of the second electrical connector (601); The first electrical connector (501) further comprises at least two first electrical contacts (513a, 513b), the at least two first electrical contacts (513a, 513b) being received in the internal connector space (545) and mating with corresponding electrical contacts (613a, 613b) of the second electrical connector (601); an end face or distal end face (522a, 522b) of each of the first electrical contacts (513a, 513b) at least partially abutting a respective mating side face (622a, 622b) of a corresponding electrical contact receptacle (615a, 615b); the abutment of all the electrical contact pairs (513a-613a, 513b-613b) is fixed by the inclined arrangement of the first housing (503) relative to the mating second housing (603) with respect to the mating axis (AX); Lug-free electrical connector assembly.

13. The housing (503) of the first electrical connector (501) is coupled or screwed onto the second electrical connector (601); tilting of the first housing (503) relative to the mating second housing (603) is made possible by a clearance between a first mechanical coupling device of the first electrical connector (501) and a second mechanical coupling device of the second electrical connector (601); the first mechanical coupling device is an external thread (535) and the second mechanical coupling device is an internal thread (635); 13. The lugless electrical connector assembly of claim 12.

14. In the tilted position, the mutually facing surfaces (523, 623) of the first housing (503) and the second housing (603) only partially abut.

13. The lugless electrical connector assembly of claim 12.

15. The protrusion (69) of the lever (49) is hemispherical. An electrical connector (1) according to claim 4.

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