Plug connector assembly and plug connector system

Abstract

The present invention - A plug connector (1) having a plug connector housing (2) having a cable exit section (3); - A counterpart plug connector (4) equipped with a counterpart plug connector housing (5) and / or mounted on a component housing (81); - A locking structure (6) placed in the plug connector housing (2), preferably in the cable exit section (3); - A relative locking structure (7) placed in the relative plug connector housing (5) and / or component housing (81); - Includes a clamping assembly (8) that is elastically and reversibly deformable, The locking structure (6) and the relative locking structure (7) can be combined with each other; The locking structure (6) and the relative locking structure (7) can take a locking position (PA) in which they mechanically contact each other in a combined state, and accordingly, movement of the cable exit section (3) is prevented. The clamping assembly (8) relates to a plug connector assembly (100) that elastically deforms in a combined state (PK) of a locking structure (6) and a relative locking structure (7) to press the locking structure (6) and / or the relative locking structure (7) into a locking position (PA).

Description

Technology Field

[0001] The present invention relates to a plug connector assembly and a plug connector system. Background Technology

[0002] Plug connector assemblies comprising plug connectors and mating plug connectors used in high-voltage applications (e.g., at least 40V, at least 100V, or at least 400V) and / or high-current applications (e.g., at least 5A, at least 10A, at least 50A, or at least 100A) are known from the prior art. Such plug connector assemblies are used, for example, in battery-electric vehicles. The mating plug connector is placed or fixed on or within components, such as, for example, an inverter, a battery, an electric machine, an electric axle (e-axle), etc. The plug connector engages with the mating plug connector along the insertion direction. The cables connected to the plug connector and / or the mating plug connector often have a large cross-sectional area, for example, at least 10mm² or even at least 50mm². To reduce the operating force required for engagement, the plug connector or the mating plug connector is often provided with a movable operating element.

[0003] DE 10 2012 218 034 A1 discloses a plug connector assembly having operating elements.

[0004] DE 10 2019 122 598 A1 discloses another plug connector assembly, wherein the sealing and vibration resistance of a plug connector connection formed once are reliably ensured through a housing locking part including a rotatable locking bracket.

[0005] DE 102012018270 A1 discloses another plug connector assembly equipped with a rotary slide lever. To connect the plug connector and the mating plug connector, the rotary slide lever is first rotated around an axis extending laterally with respect to the insertion direction to pull the plug connector and the mating plug connector. When the final position is reached, the rotary slide lever moves linearly in a plane perpendicular to the insertion direction, thereby increasing the contact force between the plug connector and the mating plug connector. Accordingly, through a kind of locking function of the operating element or a locking function of the plug connector relative to the mating plug connector, the plug connector housing and the mating plug connector housing can be connected to each other in a stable and vibration-free state by the contact force generated by the rotary slide lever.

[0006] DE 10 2018 009 478 A1 discloses another plug connector assembly having a rotary lever. A first driving element (Mitnehmerelement) is disposed on the rotary lever, and the first driving element interacts with a second driving element in a shape-coupled manner when the rotary lever is rotated. The second driving element is disposed on a slider that is linearly movably guided in a second plug connector housing, and a second locking element is disposed on the slider. The second locking element is translated relative to the first locking element disposed in the first plug connector housing by the movement of the slider, so that a shape-coupled lock can be formed or released. By such a shape-coupled lock, the tilting of the plug connector that may occur during the process of joining the plug connector due to high line weight is intended to be reduced.

[0007] The present invention is based on the recognition that if the cross-sectional area of ​​a conductor is large, the weight increases, and such conductors are often not sufficiently flexible, allowing vibrations to be transmitted with little damping. When vibrations or shaking are transmitted to such cables during operation, due to the large mass of the cable, these mechanical effects can be transmitted from the cable through the plug connector housing to the actual connection between the contact element of the plug connector and the counter contact element of the counter plug connector, which may cause the function of the connection to degrade to an undesirable degree. Furthermore, the present invention is based on the recognition that if the function of fixing the operating element or the plug connector to the counter plug connector is performed mainly or entirely in the contact point area or the adjacent area, vibrations transmitted from the cable may not be sufficiently blocked due to the lever effect resulting from the housing being formed relatively long, particularly in the case of a rectangular plug where the cable exit is not fixed, and the cable exit is rotated within a range of 60° to 120° relative to the insertion direction. In addition, the present invention is based on the recognition that a solution using slider elements to connect two (locking) elements in a shape-joining manner is structurally complex, and problems may occur during the assembly and disassembly process, which may hinder the short cycle time required in the manufacturing process.

[0008] Therefore, there is a need to provide a plug connector assembly capable of reducing or minimizing vibrations and / or tremors transmitted from the elements connected to the plug connector and / or the mating plug connector, particularly from cables, in a simple, cost-effective, reliable, and highly manufacturable manner (particularly capable of preventing or minimizing continuous relative movement of the contact point between the contact element and the mating contact element). Furthermore, the plug connector and the mating plug connector must not only be joined in a simple and rapid manner, but also be detachable, particularly with a single-hand operation.

[0009] The above necessity can be resolved by the subject matter of the present invention according to the independent claims. Preferred embodiments of the present invention are described in the dependent claims.

[0010] According to the first aspect of the present invention, a plug connector assembly is proposed.

[0011] A plug connector assembly comprises a plug connector having a plug connector housing, said plug connector housing comprising a cable exit section. Additionally, the plug connector assembly comprises a mating plug connector, said mating plug connector having a mating plug connector housing and / or said mating plug connector is mounted in a component housing. The plug connector assembly comprises a locking structure disposed in the plug connector housing. Additionally, the plug connector assembly comprises a mating locking structure disposed in the mating plug connector housing and / or the component housing. The plug connector assembly also comprises a clamping assembly elastically and reversibly deformable. The locking structure and the mating locking structure are coupled to each other, in particular mechanically.

[0012] The locking structure and the relative locking structure can assume a locked position in the combined state, and in this locked position, they are placed in a state of mechanical contact with each other, thereby preventing movement of the cable exit section. The clamping assembly elastically deforms when the locking structure and the relative locking structure are combined, and presses the locking structure and / or the relative locking structure into the locked position.

[0013] Accordingly, the plug connector housing can be mechanically fixed by preferably simple means through the interaction of the locking structure and the relative locking structure and the action of pressing these two structures into a locked position by a clamping assembly (in addition to the mechanical connection between the plug connector housing and the relative plug connector housing during the electrical contact process). As a result, vibrations or other mechanical loads (e.g., thermal cycle loads, etc.) transmitted through cables, etc., do not significantly induce relative movement between the plug connector housing and the relative plug connector housing. This protects the mechanical and / or electrical connection points of the plug connector and the relative plug connector, thereby increasing the lifespan of the plug connector assembly. In particular, if the cable exit section extends transversely with respect to the insertion direction of the plug connector and the relative plug connector (e.g., square plugs and / or 90° plugs, etc.) and / or is very long, the load on the contact point (between the contact element of the plug connector and the relative contact element of the relative plug connector) can be minimized. This is because, in this configuration, if the cable exit section is not supported or fixed, it can apply very large torque to the contact point and / or the housing component of the plug connector and / or the mating plug connector in a manner similar to a lever.

[0014] Pressing the locking structure and the relative locking structure into a locked position by means of a clamping assembly preferably allows the locking structure and the relative locking structure to be designed to have a slight gap between them during the joining or assembly process, thereby enabling them to be simply joined (when joining a plug connector and a relative plug connector), while simultaneously ensuring that this gap no longer acts in the joined state because the gap is eliminated by the pressure. Additionally, preferably, materials with particularly high rigidity and / or particularly large material thickness may be used for the locking structure and / or the relative locking structure due to this pressure, which makes the locking function particularly stable even during long periods of operation. Such designs using materials with high rigidity and / or large material thickness generally require a defined gap between the locking structure and the relative locking structure to enable a secure joining under all tolerance conditions. This gap generally allows vibrational motion to be transmitted, for example, through a cable. However, through the pressure applied by the clamping assembly, as previously described, this (necessary) gap can be neutralized in the joined state. Therefore, the aforementioned clearance is primarily required and acts only during the process of assembling (coupled) the plug connector to the mating plug connector. Particularly desirable is that the clamping assembly blocks, reduces, or hinders the movement of the cable exit section in a direction opposite to the direction of motion blockage provided at the locked position by the locking structure and the mating locking structure.In this case, the movement of the cable exit section is restricted or blocked in both directions (for example, a locking assembly can block relative movement of the cable exit section or plug connector away from the counterpart plug connector or component, whereas a clamping assembly can block movement of the cable exit section or plug connector toward the counterpart plug connector or component).

[0015] The plug connector assembly may be designed to deliver, for example, high power (e.g., at least 1 kW), or high current and / or high voltage.

[0016] A plug connector may be configured to be connected to a mating plug connector, for example. The plug connector and the mating plug connector may be coupled to each other along the insertion or fitting direction, or may already be coupled. The plug connector may be equipped with, for example, an electrical contact element. The mating plug connector may be equipped with, for example, an electrical mating contact element. The cable exit section may extend along the cable discharge direction, for example.

[0017] The insertion direction can be, for example, the Z direction. This forms an orthogonal coordinate system together with the X direction and the Y direction. The cable discharge direction can be, for example, the K direction, which can be extended parallel to the insertion direction, for example, or can be extended at an angle to the insertion direction, for example, in a direction rotated 90° relative to the insertion direction.

[0018] The locking structure and the relative locking structure may be referred to as a locking assembly or may be elements of a locking assembly. Accordingly, the locking assembly may include or be equipped with a locking structure and a relative locking structure.

[0019] The lock position can be taken by the lock assembly, or the lock assembly can be located in the lock position. In this case, the lock structure and the relative lock structure are in a state of mechanical contact, specifically in the blocked position.

[0020] On the one hand, the locking structure, relative locking structure, or locking assembly and on the other hand, the clamping assembly may be, for example, separate components or elements.

[0021] On the one hand, the locking structure and the relative locking structure or the locking assembly and on the other hand, the clamping assembly may be spaced apart from each other even when the locking structure and the relative locking structure are combined. In other words, they may be spatially separated from each other. It is also possible for them to be formed adjacent to each other, for example, by only a few millimeters. In this way, functional separation between individual components is achieved. As a result, preferably, the material and / or shape (e.g., material thickness, etc.) for the locking function can be designed differently from the material and / or shape for the pressing function.

[0022] The locking structure can be placed, for example, within or on the cable exit section.

[0023] The clamping assembly can be positioned, for example, between a plug connector housing on one side and a mating plug connector housing and / or component housing on the other.

[0024] The locking structure and the relative locking structure can be formed to be latching-coupled to each other, for example, and / or formed to be coupled to each other by a shape-coupled method, and / or formed to be coupled to each other by a friction-coupled method. This preferably enables particularly simple and rapid coupling and separation of the two structures, and is possible in particular without additional auxiliary means such as a screwdriver. For example, there is no need to form a complex screw fastening structure.

[0025] In the locked position, movement of the cable exit section is restricted or prevented, particularly with respect to the mating plug connector housing and / or component housing. In particular, movement in the lateral direction with respect to the cable exit direction is restricted or prevented. This reduces or prevents the load applied to the electrical contacts or contact points of the plug connector and the mating plug connector, as well as the load applied to the mechanical components of the plug connector housing and / or the mating plug connector housing, which is particularly preferably applied.

[0026] To ensure the effective functioning of the locking structure and the relative locking structure, it is possible for the relative locking structure not to be placed directly on the relative plug connector, but instead to be placed on an element, such as a component, that is rigidly connected to the relative plug connector or the relative plug connector housing. In this case, the relative locking structure can be functionally assigned to the relative plug connector in terms of mobility. The relative plug connector can be mounted on or within such an element, namely the component. In principle, in such cases, the element on which the relative plug connector is mounted or mountable can be considered to be contained within the relative plug connector housing in the broadest sense.

[0027] The locking structure and / or the relative locking structure may contain a material selected from the group consisting of plastic, metal and spring steel, particularly as the main material.

[0028] The locking structure can be formed integrally with, for example, the plug connector housing. This can be formed from, for example, the same material as the plug connector housing, and preferably from the same manufacturing process.

[0029] The relative locking structure may be formed integrally with, for example, the relative plug connector housing and / or component housing. This may be formed from, for example, the same material as the relative plug connector housing and / or component housing, and preferably from the same manufacturing process.

[0030] Unless otherwise noted, the term "equip" is used synonymously with the term "include."

[0031] According to one embodiment, when a plug connector and a counterpart plug connector are coupled to each other, a locking structure and a counterpart locking structure are coupled to each other.

[0032] Preferably, this allows the contact point to be protected from being affected so that as large a portion as possible of vibrations, vibratory motions, or other mechanical loads introduced from the outside are transmitted to the contact point while the plug connector and the mating plug connector are coupled.

[0033] In a non-coupled or not fully coupled state, the locking structure and the relative locking structure may not be coupled to each other. This allows, for example, a plug connector and a relative plug connector to be coupled with a particularly small force, because the possible coupling force does not overlap with the insertion force required to form electrical contact.

[0034] According to one embodiment, the locking structure is formed as a latching hook, and the relative locking structure is formed as a tab having a latching opening. This provides a locking assembly that is particularly simple, low-cost, robust, and highly assembly-safe, which can be easily closed and also easily reopened (when removing the plug connector).

[0035] The latching hook may be formed, for example, as a fixed or rigid latching hook or as an elastically reversibly movable latching hook. The latching hook may be formed, for example, as a particularly stable and / or elastically immovable latching hook. In other embodiments, the latching hook may be formed to be elastically reversibly movable.

[0036] The tab can be formed, for example, as an elastically reversibly movable tab, or as a fixed or rigid tab.

[0037] Alternatively or additionally, the relative locking structure is formed with a latching hook, and the locking structure is formed with a tab having a latching opening.

[0038] The latching hook may be formed, for example, as a fixed or rigid latching hook or as an elastically reversibly movable latching hook. The latching hook may be formed, for example, as a particularly stable and / or elastically immovable latching hook. In other embodiments, the latching hook may be formed to be elastically reversibly movable.

[0039] The tab can be formed, for example, as an elastically reversibly movable tab, or as a fixed or rigid tab.

[0040] According to one embodiment, the plug connector assembly comprises a plurality of pairs consisting of a locking structure and a relative locking structure.

[0041] This preferably ensures redundancy, so that even if one locking assembly (i.e., a pair of locking and mating locking structures) is damaged or fails, the contact point continues to be protected from the inflow of external mechanical loads (e.g., vibration). Additionally, this preferably allows the contact point to be isolated from external mechanical loads particularly effectively. Additionally, this preferably allows for the use of locking assemblies designed in smaller sizes, for example in situations where space is limited, and the required force can be secured by multiple structures. Finally, this allows for the placement of locking assemblies at all or at least multiple critical points where external mechanical force is expected to flow into the contact point and / or particularly large torque is expected to act on the contact point, for example in the case of larger plug connectors and / or mating plug connectors, thereby effectively preventing or at least minimizing the inflow of mechanical loads to the contact point.

[0042] According to one embodiment, the clamping assembly comprises a clamping structure and a relative clamping structure, wherein the clamping structure is elastically and reversibly formed, and the relative clamping structure elastically deforms the clamping structure when the locking structure and the relative locking structure are combined.

[0043] This allows the clamping assembly to preferably be operated by two partners interacting in a defined manner. Additionally, this preferably allows the clamping assembly to reliably and continuously press the locking assembly into a locked position. In other words, at the latest when a coupled state between the locking structure and the relative locking structure is reached, the clamping assembly is elastically deformed, specifically to apply a restoring force in the direction opposite to the direction of the applied force (especially with respect to the plug connector and / or the relative plug connector), thereby pressing the locking assembly into a locked position.

[0044] It is self-evident that a relative clamping structure can be formed to have, for example, bending stiffness (i.e., not elastically reversible). However, a relative clamping structure can also be formed to be elastically reversible.

[0045] According to one embodiment, a clamping structure is disposed in a plug connector housing, and a relative clamping structure is disposed in a relative plug connector housing and / or a component housing.

[0046] This ensures that an elastically reversible component (clamping structure) is always present, which is preferable. This is because the operator can verify whether the elastic component is present when assembling the plug connector to the cable or cables. For example, costly production line shutdowns caused by the omission of a clamping element during vehicle production can be prevented in advance through the visual inspection of the plug connector.

[0047] Alternatively or additionally, a relative clamping structure is placed in the plug connector housing, and a clamping structure is placed in the relative plug connector housing and / or component housing.

[0048] This allows the plug connector housing to be manufactured particularly simply and inexpensively. By placing the clamping structure in the mating plug connector housing and / or component housing, there is an advantage that the clamping structure can be replaced relatively simply if damaged. This is because there is no need to remove or replace the already assembled cable harness.

[0049] According to one embodiment, the clamping structure and / or the relative clamping structure contain a material selected from the group consisting of rubber, plastic, metal and spring steel, particularly as the main material.

[0050] The use of rubber has the effect of providing a particularly simple and inexpensive clamping structure and / or relative clamping structure.

[0051] The use of plastic enables the clamping structure and / or the relative clamping structure to be manufactured by an injection molding process, thereby allowing them to be manufactured at a very low cost, particularly together with the plug connector housing and / or the relative plug connector housing and / or the component housing. This makes it particularly desirable to form the structures integrally with the corresponding housings (at least partially).

[0052] The use of metal has the effect of providing a particularly robust clamping structure and / or a relative clamping structure. In addition, in some cases, it is also preferably possible to manufacture it integrally with a component housing formed of or containing metal.

[0053] The use of spring steel has the effect of providing particularly excellent elasticity and / or rigid clamping structures and / or relative clamping structures. This offers the advantage of being able to generate very large clamping forces even with small structure(s) sizes.

[0054] According to one embodiment, a relative clamping structure has a relative clamping structure protrusion protruding toward a clamping structure, and the clamping structure has a receiving structure for receiving the relative clamping structure protrusion, and in a state where a locking structure and a relative locking structure are combined, the relative clamping structure protrusion is received within the receiving structure and the clamping structure is elastically deformed, and the receiving structure is provided to restrict lateral movement of the relative clamping structure protrusion.

[0055] Preferably, this prevents the ingress of large motion amplitudes in a direction parallel to the clamping direction (by the locking assembly in the locked position), and also restricts or prevents movement in the lateral direction relative to this direction. Accordingly, the (electrical) contact points are continuously, reliably, and effectively protected from wear (e.g., wear due to friction or abrasion), as well as from temporary loss of contact, poor contact, and / or discharge. Additionally, the mechanical connection between the plug connector housing and the mating plug connector housing is also preferably protected from damage or degradation of material stability. In other words, this provides a plug connector assembly that is particularly robust and highly durable.

[0056] The relative clamping structure protrusion can be formed, for example, as a rib.

[0057] The elastic deformation of the clamping structure can occur, for example, parallel to the insertion direction of the plug connector and the mating plug connector.

[0058] Particularly preferably, the receiving structure may be configured to restrict the movement of the relative clamping structure protrusion relative to the relative plug connector housing and / or component housing in the transverse direction with respect to the cable discharge direction.

[0059] According to one embodiment, the clamping structure has a clamping structure protrusion protruding toward a plug connector housing, and the clamping structure has a deformation element extending substantially laterally with respect to the clamping structure protrusion, the deformation element being particularly elastically and reversibly deformable and connected to the clamping structure protrusion, and in particular, a cavity is formed between the deformation element and the relative plug connector housing and / or component housing.

[0060] This allows for the provision of a particularly effective clamping assembly with minimal material usage. The cavity enables particularly large (spatial) elastic deformation, which facilitates, for example, compensating for tolerances in the locking assembly.

[0061] It is evident that exactly one clamping structural protrusion can be provided. In this case, for example, an inverted "L" shape or a "T" shape can be used. This enables a particularly simple and space-saving structure.

[0062] In addition, it is evident that in other embodiments, two or more clamping structural protrusions may be provided. The deformation element may be positioned like a bridge deck on a protrusion, for example, a bridge pier. This enables the configuration of a clamping structure that is particularly stable and flexibly adjustable.

[0063] According to one embodiment, the deformation element is formed integrally with the clamping structure protrusion.

[0064] This provides a clamping structure that can be manufactured particularly easily with only a single manufacturing process.

[0065] Alternatively, a deformation element may be placed on the at least one clamping structure protrusion.

[0066] This allows the (at least one) clamping structure protrusion and the deformation element to be manufactured at different stages (for example, significantly simplifying the design of the injection molding die), and also allows different materials to be used for the (at least one) clamping structure protrusion and the deformation element. This enables different functions to be assigned to individual elements and / or individual materials. For example, the (at least one) clamping structure protrusion may be formed of a rigid plastic with a relatively thick wall thickness. Here, it only needs to perform the function of transmitting (substantially static) force. On the other hand, the deformation element may be formed of a metal, for example, spring steel. The deformation element may be formed relatively thin, for example (for example, with a material thickness of up to 1 mm). In this case, substantially high elasticity (large displacement possible without plastic deformation, high restoring force, etc.) is important.

[0067] The deformation element can be positioned, for example, in a non-destructively detachable manner on a clamping structure protrusion. This offers the advantage of facilitating assembly and disassembly (for maintenance).

[0068] According to one embodiment, a plug connector or a mating plug connector is provided with an operating element movable between a first position and a second position to reduce the operating force when coupling the plug connector and the mating plug connector, in particular, a lever and / or a slider, said operating element is provided with a locking element, said locking element is configured to form a coupling between a locking structure and a mating locking structure by moving a mating locking structure from a non-coupled position to a coupled position in the direction of the locking structure.

[0069] The interaction between the locking element and the relative locking structure provides the advantage that the relative locking structure moves and consequently receives mechanical load, particularly when the plug connector is coupled with the relative plug connector.

[0070] Overall, this allows the locking structure and the relative locking structure to be mechanically coupled only at specific locations of the operating element. That is, even if the locking structure and the relative locking structure are already overlapping at an earlier location of the operating element (or between the plug connector and the relative plug connector), coupling does not yet occur. This can provide the advantage of reduced operating force. This is because, for example, there is no need to overcome high insertion force (e.g., beak peak) between at least one contact element and at least one relative contact element first, and additionally overcome mechanical friction force between the locking structure and the relative locking structure. Furthermore, preferably, this allows for true geometric coupling between the locking structure and the relative locking structure (e.g., 90° corners and 90° undercuts), which cannot be applied in conventional methods (slid overlapping until coupling). This is because, in these 90° corners and 90° undercut structures, sliding release of the locking structure and the relative locking structure is impossible, particularly when separating the plug connector, or the risk of damage to the locking structure and / or the relative locking structure increases.

[0071] In the proposed embodiment, the relative locking structure can be formed elastically and reversibly, and can be configured so as not to be coupled with the locking structure in the resting position (a state in which no force is applied by the locking element) (even in the case of overlap).

[0072] Alternatively or additionally, the operating element and / or the locking element may be configured to move the relative locking structure from a non-coupled position to a coupled position in a first position, and to move the relative locking structure from a coupled position to a non-coupled position in a second position or in the process of moving to a second position (e.g., from the first position) (e.g., by a cam structure cooperating with a protrusion). In such a configuration, even if the relative locking structure is not designed to be sufficiently elastic and reversible to return to a position not coupled with the locking structure without a separate external force, a secure lock can be achieved (e.g., when closing the operating element such as a lever or slider) and a secure unlock can be achieved (e.g., when opening the operating element such as a lever or slider) by simple means.

[0073] Alternatively or additionally, the operating element may be provided with a locking element, said locking element may be configured to form a coupling between the locking structure and the relative locking structure by moving the locking structure from a non-coupling position to a coupling position in the direction of the relative locking structure.

[0074] The interaction between the locking element and the locking structure offers the advantage of being able to inspect the cooperative operation of the locking element and the locking structure before assembling the plug connector to the mating plug connector (considering that the operating element is often placed in the plug connector).

[0075] Overall, this allows the locking structure and the relative locking structure to be mechanically coupled only at specific locations of the operating element. Additionally, even if the locking structure and the relative locking structure are already overlapping at an earlier location of the operating element (or between the plug connector and the relative plug connector), coupling does not yet occur. This can provide the advantage of reduced operating force, because, for example, there is no need to overcome high insertion force (e.g., beak peak) between at least one contact element and at least one relative contact element first, and additionally overcome mechanical friction force between the locking structure and the relative locking structure. Furthermore, preferably, this allows for true geometric coupling between the locking structure and the relative locking structure (e.g., 90° corners and 90° undercuts), which cannot be applied in conventional methods (slid-overlapping until coupling). This is because, in these 90° corners and 90° undercut structures, sliding release of the locking structure and the relative locking structure is impossible, particularly when the connector is separated, or the risk of damage to the locking structure and / or the relative locking structure increases.

[0076] In the proposed embodiment, for example, the locking structure can be formed elastically and reversibly, and can be configured so as not to engage with the relative locking structure in the resting position (a state in which no force is applied by the locking element) (even in the case of overlap).

[0077] Alternatively or additionally, the operating element and / or the locking element may be configured to move the locking structure from a non-coupled position to a coupled position in a first position, and to move the locking structure from a coupled position to a non-coupled position in a second position or in the process of moving to a second position (e.g., from the first position) (e.g., by a cam structure cooperating with a protrusion). In such a configuration, even if the locking structure is not designed to be sufficiently elastic and reversible to return to a position not coupled with the relative locking structure without a separate external force, secure locking may be achieved (e.g., when closing the operating element such as a lever or slider) and secure unlocking may be achieved (e.g., when opening the operating element such as a lever or slider) by simple means.

[0078] It is also possible to provide two or more locking assemblies. In this case, a first locking element may interact with a relative locking structure of one locking assembly (e.g., on one side of a plug connector), and a second locking element may interact with a locking structure of another locking assembly (e.g., on the other side of a plug connector). Of course, in this configuration, it is also possible for the locking elements to each interact with relative locking structures or to each interact with locking structures.

[0079] In one embodiment, the operating element is configured to engage a plug connector and a counterpart plug connector when moving from a first position to a second position, and at a third position located between the first and second positions, the insertion process for forming contact between the plug connector and the counterpart plug connector is completed. When the operating element moves from the third position to the second position, the locking element is configured to engage with a counterpart locking structure and move in the direction of the locking structure.

[0080] Preferably, there is no need to apply additional force to combine the locking structure and the mating locking structure up to the third position, where the actual insertion process (for electrical coupling between the plug connector and the mating plug connector) is completed. This facilitates the process of coupling the plug connector and the mating plug connector. Furthermore, the risk of the locking structure and the mating locking structure unintentionally colliding with each other due to manufacturing or assembly tolerances, thereby causing damage or interfering with the coupling process, is reduced. Consequently, different functions can be performed along the movement path of the operating element. Even if a problem occurs in the section from the third position to the second position, at least the electrical connection is established.

[0081] Alternatively or additionally, the operating element may be configured to combine the locking element with the locking structure and move it in the direction of the relative locking structure when moving from the third position to the second position.

[0082] In this case as well, the same considerations and advantages described for the first alternative apply.

[0083] A second aspect of the present invention relates to a plug connector system.

[0084] The above-described plug connector system includes a component having a component housing and a plug connector assembly described above, and a mating plug connector is mounted on the component housing.

[0085] The present invention can provide a plug connector system that is particularly simple in structure, inexpensive to manufacture, highly reliable, robust against external mechanical influences, and has a long service life.

[0086] The above components may be, merely as examples, an inverter, (high-voltage) battery, electric machine, electric axle, or similar. Brief explanation of the drawing

[0087] Further features and advantages of the present invention will become apparent to those skilled in the art through the following description of exemplary embodiments with reference to the accompanying drawings. However, such description should not be construed as limiting the present invention. Figure 1 is a schematic cross-sectional view of a plug connector system. FIG. 2a is a schematic perspective view of a plug connector system. FIG. 2b is a schematic cross-sectional view of a part of the plug connector assembly of the plug connector system of FIG. 2a. FIG. 2c is an enlarged detailed view of the plug connector assembly of FIG. 2b. Figure 3 is a schematic cross-sectional view of a part of a plug connector assembly. FIG. 4a is a perspective view of a part of a plug connector assembly. FIG. 4b is a perspective detail view of a part of the mating plug connector of the plug connector assembly of FIG. 4a. FIG. 4c is a schematic cross-sectional view of a part of the plug connector assembly of FIG. 4a. FIG. 5a is a schematic side view of a plug connector assembly and a schematic front view showing details of the plug connector assembly. FIG. 5b is a schematic front view of the plug connector assembly of FIG. 5a at the third position of the operating element. FIG. 5c is a schematic front view of the plug connector assembly of FIG. 5a at the second position of the operating element. Specific details for implementing the invention

[0088] FIG. 1 is a schematic cross-sectional view of a plug connector system (200) obtained through internal simulation and testing performed by the applicant, intended to explain the general relationship related to the present invention.

[0089] The plug connector system (200) includes a component (80) (e.g., an inverter for an electric vehicle (82)) and a component housing (81). The plug connector system (200) also includes a plug connector assembly (100).

[0090] The plug connector assembly (100) comprises a plug connector (1) having a plug connector housing (2) having a cable exit section (3). The plug connector assembly (100) also comprises a relative plug connector (4) having a relative plug connector housing (5), and the relative plug connector (4) or the relative plug connector housing (5) is mounted to a component housing (81) using a plurality of screws (51). The plug connector assembly (100) also comprises a locking structure (6) in the form of a latching hook (9) implemented herein as a fixed latching hook (9) or a non-movable or non-flexible latching hook (9). The locking structure (6) is positioned in the plug connector housing (2) and, for example, in the cable exit section (3). The plug connector assembly (100) also comprises a relative locking structure (7) formed herein, for example, as a (relatively thin) tab (10) having a latching opening (11), particularly an elastically reversibly movable tab (10). The relative locking structure (7) is exemplarily placed in the relative plug connector housing (5), but in other cases, it may be alternatively or additionally placed in the component housing (81). The locking structure (6) and the relative locking structure (7) are joined together here (generally, they may be joined together) and are latched together in a snap lock or clip lock manner. The joined state or joined position is indicated below by the reference numeral PK. The locking structure (6) and the relative locking structure (7) may take a locked position (PA) in the joined state (here, a total of two locked positions (PA) are indicated, one each at the top of the tab (10) and the top of the through opening (11) of the tab (10)). In this locked position, the two structures are mechanically in contact with each other, preventing movement of the cable exit section (3), particularly with respect to the relative plug connector housing (5) and / or the component housing (81).

[0091] The latching hook (9) has a latching protrusion (54) that engages with the latching opening (11).

[0092] The plug connector (1) is coupled with the relative plug connector (4) along the insertion direction (Z) (also called the Z direction (Z)). The insertion direction (Z) forms an orthogonal coordinate system together with the X direction (X) and the Y direction (Y).

[0093] Here, the plug connector (1) and the mating plug connector (4) are designed for the transmission of high current (at least 1A, preferably at least 10A, particularly preferably at least 50A) and / or high voltage (at least 40V, preferably at least 100V, particularly preferably at least 200V, most preferably at least 400V or even at least 800V).

[0094] The plug connector housing (2) includes a cable (40) having an insulator (41) and a current conductor (42) into which the cable (40) is inserted or a cable exit section (3) through which the cable (40) exits from the plug connector (1). The plug connector housing (2) can accommodate exactly one cable (40) or multiple cables (40). The conductor (42) is connected to a contact element (43) inside the plug connector housing (2), and the contact element (43) has, for example, at least one contact plate (44). The contact element (43) is designed, for example, as a female contact element. The contact element (43) is electrically connected to a counterpart contact element (50) of the counterpart plug connector (4) to form a contact section (52). The counterpart contact element (50) is designed, for example, as a male contact element.

[0095] To allow the operator to handle high insertion forces more easily, the plug connector (1) is provided with an operating element (20) that reduces the operating force, wherein the operating element (20) is in the form of a lever (21). The lever (21) can rotate from a first position (P1) (start position) to a second position (P2) (final position). An arm not visible here or a part not visible here of the arm of the lever (21) may, for example, have a cam structure built into it. This cam structure may work in conjunction with a bolt or pin not visible here of the opposite plug connector (4). In other cases, a rack and pinion combination or something similar may be used. When the lever (21) is moved from the first position (P1) to the second position (P2), the plug connector (1) is pulled toward the opposite plug connector (4), and the contact element (43) and the opposite contact element (50) are mechanically coupled and electrically connected.

[0096] The cable exit section (3) extends parallel to the cable discharge direction (K), where K is parallel to the X direction (X) and thus perpendicular to the insertion direction (Z). Thus, the plug connector (1) is designed as an angled plug or a 90° plug. A 180° plug has, for example, a cable exit section (3) parallel to the insertion direction (Z).

[0097] The conductor (42) may be composed of metal, for example, to conduct current with minimal resistance. The conductor (42) may contain, for example, copper, a copper alloy, or aluminum, particularly as the main material. The conductor (42) may have a large cross-sectional area, for example, at least 5 mm², at least 10 mm², at least 25 mm², at least 50 mm², or at least 90 mm², to transmit high current and / or voltage with minimal resistance, especially without overheating. Due to this large cross-sectional area, the conductor (42) is relatively rigid or less flexible and is also heavy. This weight acts on the plug connector housing (2) through the cable exit section (3). Even in the absence of external vibration or mechanical load, this weight generates a large torque at the mechanical interface between the plug connector housing (2) and the counterpart plug connector housing (5). This torque also acts on the electrical contact section (52), or the contact point consisting of the contact element (43) and the counterpart contact element (50). When vibration occurs in a system (e.g., an electric vehicle) equipped with a plug connector assembly (100), this vibration can be transmitted through the cable (40) or conductor (42) to the cable exit section (3) and then to the plug connector housing (2). Due to the high impact force (large mass of the conductor (42)) and the lever arm of the cable exit section (3), this vibration can be transmitted to the electrical interface, degrading its function or causing premature wear. This problem can also occur with a 180° plug, which is not shown here, but in this case, the lever arm of the moving mass is at least shorter.

[0098] To minimize or prevent mechanical loads (e.g., thermal alternating loads that may cause vibration or stress) from being transmitted onto or into the contact section (52) or generally the plug connector housing (2), the plug connector assembly (100) is equipped with the locking structure (6) and the relative locking structure (7) described above, and these structures may be elements of the locking assembly (30). This locking assembly (30) supports or (nearly) secures the cable exit section (3) against the relative plug connector (4) or component (80). As a result, vibrations transmitted through the conductor (42) or cable (40) prevent the entire plug connector housing (2) from moving easily, thereby reducing the torque transmitted to the contact section (52).

[0099] The locking structure (6) is supported on one side at the top (free end) of the tab (10) in the plug connector assembly (100) shown in FIG. 1 (particularly together with the protrusion of the latching hook (9) separated from the latching hook (9) by a notch), here forming a (first) locking position (PA). This prevents the cable exit section (3) from moving along the insertion direction (Z) (here downward). The locking structure (6) is supported on the other side at the top (in FIG. 1) of the latching opening (11), here forming a (second) locking position (PA). This prevents the cable exit section (3) from moving in the opposite direction to the insertion direction (Z) (here upward). The tab (10) is positioned so that the latching opening (11) faces the X direction (X).

[0100] However, in the plug connector assembly (100) of FIG. 1, since both housings (one side being the plug connector housing (2) and the other side being the counterpart plug connector housing (5) or component housing (81)) are made of rigid or hard material and have a shape, and considering manufacturing tolerances, a problem arises in that a small gap exists or is required in at least one of the two locking positions (PA). Otherwise, assembly or coupling would not be properly achieved, or the coupling between the locking structure (6) and the counterpart locking structure (7) would not be sufficient, making it impossible to achieve the goal of stably and permanently reducing vibration transmission. However, due to this gap, the plug housing or plug connector housing (2) can still move up and / or down to some extent (parallel to the insertion direction (Z)). This may have a negative long-term effect on the contact section (52), especially when the lever arm is large (e.g., when the cable exit section (3) is long and / or when the distance from the plug connector (1) to the first fixed point of the cable (40) to the outside of the plug connector (1), e.g., the car body, component (80), etc. is long), or may even cause fatigue at the mechanical interface of the plug connector housing (2) or the opposite plug connector housing (5).

[0101] For the same reason, the latching opening (11) must be sufficiently larger than the latching hook (9) in the Y direction (Y) so that the latching hook (9) and the latching opening (11) can be combined, so lateral movement (movement parallel to the Y direction (Y)) is also possible.

[0102] Another problem is that when the plug connector is opened (when the lever (21) moves from the second position (P2) toward the first position (P1)), the latching hook (9) must have an angle of less than 90° at the point of contact with the tab (11) or an insertion or withdrawal slope so that the latching hook (9) can be separated from the engagement or coupling with the tab (10) by the latching hook (9) with sufficient force to laterally displace the tab (10) upward (opposite to the insertion direction (Z)), particularly so that it can be separated without destruction. Therefore, an angle of (nearly) 90° of the latching hook (9), which is actually advantageous for blocking the upward movement of the plug connector (1) or cable exit section (3), cannot be implemented here. In FIG. 1, the latching hook (9) extends from the top (below the notch) in a 90° shape preferred for latching connection, substantially parallel to the X direction (X), to form a complete shape connection with the tab (10).

[0103] FIG. 2a illustrates a schematic perspective view of a plug connector system (200) comprising a plug connector assembly (100) and a component (80). Here, the component (80) is designed, for example, as an inverter (82).

[0104] FIG. 2b shows a schematic cross-sectional view of a part of the plug connector assembly (100) of the plug connector system (200) of FIG. 2a.

[0105] FIG. 2c shows an enlarged detailed view of the plug connector assembly (100) of FIG. 2b.

[0106] Figures 2a, 2b, and 2c will be explained together below.

[0107] As with FIG. 1, the plug connector assembly (100) of FIG. 2a to FIG. 2c comprises a plug connector (1) having a plug connector housing (2) (also designed as a 90° plug connector) and a counterpart plug connector (4) having a counterpart plug connector housing (5), wherein the counterpart plug connector (4) is mounted in the component housing (81) of the component (80). Additionally, the plug connector assembly (100) comprises a locking structure (6) disposed in the plug connector housing (2), preferably in the cable exit section (3) of the plug connector housing (2), and a counterpart locking structure (7) disposed exemplarily in the counterpart plug connector housing (5), but which may alternatively or additionally be disposed in the component housing (81) depending on the case. Unlike the plug connector assembly (100) of FIG. 1, the plug connector assembly of FIG. 2a through 2c includes an elastically and reversibly deformable clamping assembly (8), which is exemplarily positioned between the plug connector housing (2) and the counterpart plug connector housing (5) (in some cases, alternatively or additionally, it may be positioned, for example, between the plug connector housing (2) and the component housing (81)). The locking structure (6) and the counterpart locking structure (7) can be coupled to each other (in which they are already coupled at the coupling position (PK), and in particular, can be latched coupled to each other (in which they are latched coupled); in the coupled state (PK), the locking structure (6) and the counterpart locking structure (7) can take a locking position (PA) in which they mechanically contact each other, thus preventing movement of the cable exit section (3), in particular, with respect to the counterpart plug connector housing (5) and / or the component housing (81). The clamping assembly (8) is elastically deformed while the locking structure (6) and the relative locking structure (7) are combined, and presses the locking structure (6) and / or the relative locking structure (7) to the locking position (PA).

[0108] In this way, the problem of play between the locking structure (6) and the relative locking structure (7) of the plug connector assembly (100) of FIG. 1 is resolved because the clamping assembly (8) eliminates play in the locking assembly (30) and ensures that the locking assembly (30) is always in one locking position (PA) (here, the locking position (PA) between the bottom of the latching hook (9) and the bottom of the latching opening (11) of the tab (10), see FIG. 2b). This reduces vibration or movement transmitted to the cable exit section (3) and the plug connector housing (2), thereby preferably reducing the mechanical load applied to the contact point (52) (not visible here, but see FIG. 1).

[0109] As can be clearly seen in FIGS. 2a and 2b, when the plug connector (1) and the counterpart plug connector (4) are combined, the locking structure (6) and the counterpart locking structure (7) are combined.

[0110] In the plug connector assembly (100) illustrated in FIGS. 2a through 2c, the relative locking structure (7) is designed as a latching hook (9), which is illustrated herein only as an exemplary fixed latching hook (9) (movable, elastically reversibly movable, or rotary latching hook (9) are also possible). The locking structure (6) is designed as a tab (10) having an exemplary latching opening (11), which is illustrated herein only as an exemplary elastically reversibly movable tab (10) (fixed or rigid tab (10) are also possible). The latching hook (9) has a latching projection (54) that engages with the latching opening (11).

[0111] As can be seen in FIGS. 2a and 2b, the plug connector assembly (100) includes a plurality of pairs of locking structures (6) and relative locking structures (7), i.e., a plurality of locking assemblies (30). In the illustrated exemplary plug connector assembly (100), two locking assemblies (30) are provided. The plug connector housing (2) includes, exemplarily, two contact elements (43) (not shown herein) and two corresponding cables (40). The two cables (40) are each guided through a cable exit (53) of the plug connector housing (2). The locking assemblies (30) are positioned below each of the two cable exits (53), particularly approximately in the center. The latching openings (11) of the tabs (10) are parallel to the Y direction (Y) and thus perpendicular to the insertion direction (Z) and the cable discharge direction (K), and the latching hooks (9) of the relative locking structure (7) are likewise (unlike the plug connector assembly of FIG. 1, which is provided with only a single locking assembly (30), in which the latching openings are aligned parallel to the X direction (X), i.e., parallel to the cable discharge direction (K)). The latching hooks (9) face each other (are oriented inward). The cable (40) can be guided along the cable discharge direction (K), for example, from the plug connector housing (2) or, in this case, from two cable outlets (53).

[0112] The arrangement of these locking assemblies (30) effectively prevents mechanical movement introduced into the cable exit section (53) and onto the plug connector housing (2) because each cable exit (53) is assigned its own locking assembly (30). Additionally, this is desirable for ensuring redundancy in the event that, for example, one of the two locking assemblies (30) is damaged. The tab (10) and latching hook (9) are positioned transversely in the cable exit direction (K) and insertion direction (Z), thereby blocking movement parallel to the insertion direction (Z) as well as blocking or reducing movement parallel to the Y direction (Y), because the two locking assemblies (30) act as guardrails against lateral movement. Thus, the plug connector assembly (100) is very strong against external mechanical influences, very stable, and highly durable.

[0113] The clamping assembly (8) is provided with, for example, a clamping structure (12) and a relative clamping structure (13), wherein the clamping structure (12) is elastically reversible, and in the combined state (PK) of the locking structure (6) and the relative locking structure (7), the relative clamping structure (13) elastically deforms the clamping structure (12).

[0114] It is obvious that the plug connector assembly (100) may have two or more clamping assemblies (8).

[0115] The relative clamping structure (13) is exemplarily placed in the plug connector housing (2) here. The clamping structure (12) is exemplarily placed in the relative plug connector housing (5) here and may alternatively or additionally be placed in the component housing (81).

[0116] In another embodiment, (alternatively or additionally) (at least one) clamping structure (12) may be disposed in the plug connector housing (2), and (at least one) relative clamping structure (13) may be disposed in the relative plug connector housing (5) and / or component housing (81).

[0117] In the plug connector assembly (100) of FIGS. 2a to 2c, the clamping structure (12) is formed integrally with the mating plug connector housing (5) and is therefore made of the same material as the mating plug connector housing (5). This material may include plastics such as PBT, PA, PP, etc.

[0118] The relative clamping structure (13) is formed integrally with the plug connector housing (2) as an example here, and is therefore made of the same material. This material may include plastics such as PBT, PA, PP, etc.

[0119] The relative clamping structure (13) has a relative clamping structure protrusion (14) in the form of a rib (15) that protrudes toward the clamping structure (12) as exemplarily shown here. This rib (15) protrudes downward from the cable exit (53) (toward the relative plug connector (4)). The clamping structure (12) includes a receiving structure (16) that receives the relative clamping structure protrusion (14). The relative clamping structure protrusion (14) is received within the receiving structure (16) in a combined state (PK) where the locking structure (6) and the relative locking structure (7) are combined (as shown herein), and elastically (especially elastically reversibly) deforms the clamping structure (12) particularly parallel to the insertion direction (Z). The receiving structure (16) limits the lateral movement of the relative clamping structure protrusion (14), particularly the relative movement relative to the relative plug connector housing (5) and / or component housing (81) in the lateral direction with respect to the cable discharge direction (K).

[0120] This further improves the lateral stability of the plug connector housing (2). This is because, in addition to the guardrail function provided by the two locking assemblies (30), the receiving structure (16) provides an additional guardrail function that limits or blocks the movement of the cable exit section (3) and consequently the plug connector housing (2) by limiting or blocking the lateral movement of the relative clamping structure protrusion (14).

[0121] The receiving structure (16) is designed in a U-shape, and the rib (15) is received between the two legs of the U-shape. The two legs of the U-shape are spaced apart from each other, for example, by the same spacing as the width of the rib (15). This ensures particularly excellent and precise lateral guidance. The open end of the U-shape is provided with an insertion slope on each leg so that the rib (15) is safely and securely inserted between the two legs during the insertion process. The rib (15) or the relative clamping structure protrusion (14) is positioned here, exemplarily, in the substantial center (in the Y direction), that is, between the two cable exits (53).

[0122] The clamping structure (12) has at least one clamping structure protrusion (17) protruding toward the plug connector housing (2) (two such clamping structure protrusions (17) are provided in FIGS. 2a through 2c). The clamping structure (12) has a deformation element (18) that extends substantially laterally with respect to the clamping structure protrusion (17), and the deformation element (18) is particularly elastically reversibly deformable and connected to the clamping structure protrusion (17). Between the deformation element (18) and the relative plug connector housing (5) and / or component housing (81), a cavity (19) is formed, here only exemplarily.

[0123] The deformation element (18) is formed integrally with the clamping structure protrusion (17) as an example here (as an example only: with two clamping structure protrusions (17)).

[0124] The clamping structure (12) is, for example, a bridge or an inverted U-shape, the clamping structure protrusion (17) represents a bridge pier or a U-shaped bridge, and the deformation element (18) represents a bridge deck or a U-shaped floor. Due to the receiving structure (16) formed in the deformation element (18), the shape of the clamping structure (12) can also be seen as an "M" shape.

[0125] During the insertion process, the plug connector housing (2) is inserted into the opposing plug connector housing (5) in the insertion direction (Z). As the (flexible) tab (10) of the plug connector housing (2) and the (fixed) latching hook (9) of the opposing plug connector housing (5) make initial contact, the tab (10) is elastically bent inward. When a defined insertion depth or insertion position is reached, the opposing clamping structure (13) (in the form of the opposing clamping structure protrusion (14)) comes into contact with the clamping structure (12) of the opposing plug connector housing (5).

[0126] The subsequent insertion process (the plug connector housing (2) moving in the insertion direction (Z), i.e., downward) is made possible by the elastic clamping structure (12) of the opposing plug connector housing (5), and the clamping structure (12) is elastically deformed during this process.

[0127] In a defined additional insertion position, the latching coupling recess or latching opening (11) in the tab (10) of the plug connector housing (2) moves completely over the latching protrusion (54) of the latching hook (9), and the tab (10) is elastically returned.

[0128] Now, the restoring force of the flexible, elastic, or elastically reversible clamping structure (12) of the opposing plug connector housing (5) is applied. The clamping structure (12) tends to return to its original shape, generating a force, and as a result, the plug connector housing (2) moves upward from the "over-compressed" position (see FIG. 2a–2c). Consequently, gapless contact is made between the flexible tab (10) and the latching hook (9) or the latching protrusion (54), and the (upper) locking position (PA) of the locking assembly (30) is set. Here, for example, gapless contact is made in both directions with continuous contact of the clamping assembly (8) between the opposing clamping structure (13) (here, the rib (15)) of the plug connector housing (2) and the flexible clamping structure (12) of the opposing plug connector housing (5), thereby limiting and / or damping movement in both directions (here, upward and downward, i.e., in a direction parallel to the insertion direction (Z)).

[0129] The two side walls of the receiving structure (16) into which the rib (15) of the plug connector housing (2) is inserted restrict movement in the left-right direction (a direction parallel to the Y direction) as described above. When the clamping structure (12) is deformed downward during the insertion process, these two side walls move further toward each other, thereby further restricting the lateral movement freedom of the rib (15) and consequently further restricting the lateral movement freedom of the cable exit section (3). This is indicated by an arrow in FIG. 2c.

[0130] FIG. 3 shows a schematic cross-sectional view of a part of a plug connector assembly (100) that differs from the plug connector assembly (100) of FIG. 2a to 2c in the shape of the clamping assembly (8), particularly the clamping structure (12). Otherwise, the plug connector assembly (100) of FIG. 3 is very similar to that shown in FIG. 2a to 2c.

[0131] In the plug connector assembly (100) illustrated in FIG. 3, the clamping structure (12) is formed in the form of an elastomer element (23). The elastomer element (23) or the clamping structure (12) is made of a homogeneous elastic material, such as rubber, silicone, etc., as exemplarily. The clamping structure (12) is designed in the form of a block, as exemplarily. The clamping structure (12) does not include, for example, (connected) cavities (19) (where pores are not considered as cavities (19)).

[0132] The clamping structure (12) may be designed as a separate part, for example (separated from the mating plug connector housing (5) or component housing (81). Alternatively, the clamping structure (12) may be manufactured, for example, by two-component injection molding and connected integrally with, for example, the mating plug connector housing (5). In other cases, the clamping structure (12) may be formed by extending a conventional elastic element (e.g., a rubber part), such as an axial seal, correspondingly (spatially) between the plug connector housing (2) and the mating plug connector housing (5).

[0133] FIG. 4a is a perspective view showing a part of a plug connector assembly (100).

[0134] FIG. 4b is a perspective detail view showing a part of the mating plug connector (4) of the plug connector assembly (100) of FIG. 4a.

[0135] FIG. 4c is a schematic cross-sectional view showing a part of the plug connector assembly of FIG. 4a.

[0136] Figures 4a to 4c will be explained together below.

[0137] The plug connector assembly (100) of FIGS. 4a to 4c is designed to be very similar to the plug connector assembly of FIGS. 2a to 2c. The main difference lies in the design of the clamping structure (12).

[0138] As can be seen in FIGS. 4a through 4c, the clamping structure (12) has two internal clamping structure protrusions (17). These each have a free end (29) facing the cable exit section (3) only as an example. The free end (29) has a neck portion (28) shown only as an example. The neck portion (28) is surrounded, for example, by shoulders (27) on both sides (each).

[0139] Additionally, the clamping structure (12) is provided with two fixed protrusions (24), one of which is positioned on the side (in the Y direction (Y)) outside of each clamping structure protrusion (17). Along the Y direction (Y), the following sequence of elements appears: first fixed protrusion (24) - first clamping structure protrusion (17) - second clamping structure protrusion (17) - second fixed protrusion (24). The fixed protrusions (24) protrude from the mating plug connector housing (5) toward the cable exit section (3). Each of them is provided with an inwardly facing latching lug (25). They are, for example, roughly aligned with the clamping structure protrusions (17). The fixed protrusions (17) are at a height approximately equal to the shoulder height of the clamping structure protrusion (17). The fixed protrusion (24) and the clamping structure protrusion (17) are integral with the relative plug connector housing (5), which is made of the same material—only as an example—and cannot be separated without destruction.

[0140] The clamping structure (12) also comprises a deformation element (18). This deformation element (18) is made of a thin metal plate, for example, made of spring steel. The thickness of the material is, for example, up to 2 mm, preferably up to 1 mm. The deformation element (18) is, exemplarily, an inverted "U" shape with a very long and thin "U" arc, and this "U" arc forms a support element (31). The support element (31) extends substantially horizontally, or parallel to the Y direction (Y), or in the XY plane, as shown in FIGS. 4a through 4c. Two legs (32) protrude from the "U" arc or the support element (31) and each have a latching joint recess (26). The support element (31) has an opening (33) in each of the two outer sections (when viewed along the Y direction (Y)). The deformation element (18) also has a receiving structure (16) formed by two upwardly bent limiting tabs (55) in the central section. When viewed opposite to the insertion direction (Z), the limiting tabs (55) initially extend toward each other. Then, a bend occurs in the upper section, and then they move away from each other. In this way, they form a kind of insertion slope or insertion funnel for the relative clamping structure (31) in the upper region (e.g., the upper 1 / 3 or upper 1 / 4). The limiting tabs (55) act like clamps to limit or prevent lateral movement of the plug connector (1) relative to the relative plug connector (4) in the coupled state (PK) (particularly parallel to the Y direction (Y)). When the deformation element (18) is deformed in the insertion direction (Z) by the relative clamping structure (13) (especially in the combined state (PK)), the two limiting tabs (55) may move, for example, toward each other to secure the relative clamping structure (13) or the relative clamping structure protrusion (14) or rib (15) between them, or at least reduce the possible (lateral) clearance of the relative clamping structure (13) between the limiting tabs (55).

[0141] The deformation element (18) can be designed as a stamped and bent part. Limit tabs (55) are punched in two outer sections of the support element (31) and bent upward. This forms openings (33).

[0142] FIGS. 4a to 4c clearly show that the deformation element (18) can be disposed on two clamping structure protrusions (17), particularly non-destructively separable.

[0143] To this end, a support section or support element (31) of a deformation element (18) is placed over two clamping structure protrusions (17), and the outer edge or edge section of the deformation element (18) touches the shoulder (27) of the clamping structure protrusion (17). The neck portions (28) of the clamping structure protrusions (17) pass through openings (33) to restrict the movement of the support section or support element (31) in the XY plane or to fix the support section or support element (31) in this plane.

[0144] The latching joint recesses (26) of the leg (32) are latching joined with the latching lugs (25) of the fixed protrusions (24). Thus, the movement of the deformation element (18) parallel to the insertion direction (Z) is limited or blocked on one side by the support of the support element (31) on the shoulder (27), and on the other side by the latching joint of the latching lugs (25) and the latching joint recesses (26) of the leg (32). Thus, when the plug connector (1) and the opposing plug connector (4) are joined, the deformation element (18) is elastically fixed by the opposing clamping structure (13) to press the locking assembly (30) into the locking position (PA) (here, the lower end of the latching opening (11) of the tab (10) is pressed upward so that it is permanently mechanically in contact with the lower end of the latching hook (9). For example, the force applied to the deformation element (18) by the relative clamping structure (13) applied to the central part is absorbed on one side by the shoulder (27) and on the other side by the latching lug (25).

[0145] Two outer fixed protrusions (24) are provided, so there is no need to make a sharp (90°) bend immediately behind or on the opening (33), making the manufacturing and assembly of the deformation element (18) more flexible. Additionally, when force is applied by the relative clamping structure (13), the two legs (33) spread outward, so the two legs (33) are pressed more strongly in a latching connection state with the latching lugs (25). Thus, smaller latching lugs (25) can be used than when located on the outer side of the clamping structure protrusion (17).

[0146] FIG. 5a shows a side schematic view of a plug connector assembly (100) and a detailed front schematic view of a plug connector assembly (100).

[0147] FIG. 5b shows a front schematic view of the plug connector assembly (100) of FIG. 5a at the third position (P3) of the operating element (20).

[0148] FIG. 5c shows a front schematic view of the plug connector assembly (100) of FIG. 5a at the second position (P2) of the operating element (20).

[0149] Figures 5a to 5c will be described together below.

[0150] A plug connector (1) (in other embodiments, a counterpart plug connector (4)) is provided with a movable operating element (20) between a first position (P1) (e.g., initial position or starting position) and a second position (P2) (e.g., final position) to reduce the operating force when joining the plug connector (1) and the counterpart plug connector (4), wherein the operating element (20) is provided with a lever (21) as an example (alternatively or additionally, a slider or other element may be provided). The operating element (20) is provided with a locking element (22), which is designed to move the counterpart locking structure (7) from a non-joining position (PN) toward the locking structure (6) to a joining position (PK) to form a joining between the locking structure (6) and the counterpart locking structure (7).

[0151] To perform the coupling, the lever (21) is rotatably mounted, for example, on the shaft (36) of the plug connector housing (2). One lever arm of the lever (21) has a cam track (35), for example, formed with a variable distance from the shaft (36), and this cam track (35) interacts with a protrusion, pin, or bolt (34) placed in the plug connector housing (2). When the lever (21) is rotated from a first position (P1) to a second position (P2), the bolt (34) pulls the plug connector (2) toward the opposite plug connector (4) as it moves closer and closer to the shaft (36) along the cam track (35).

[0152] In another embodiment, the operating element (20) may be provided with a locking element (22), which may be designed to move the locking structure (6) from a non-coupled position (PN) to a coupled position (PK) in the direction of the relative locking structure (7), thereby forming a coupling between the locking structure (6) and the relative locking structure (7).

[0153] The operating element (20) is designed, exemplarily, here to combine the plug connector (1) and the opposing plug connector (4) when moving from the first position (P1) to the second position (P2) (see description above). At the third position (P3) between the first position (P1) and the second position (P2), the insertion process for forming contact between the plug connector (1) and the opposing plug connector (4) is completed. The operating element (20) is designed, exemplarily, here to combine the locking element (22) with the opposing locking structure (7) and move toward the locking structure (6) when moving from the third position (P3) (see FIG. 5b) to the second position (P2) (see FIG. 5c).

[0154] The three positions (P1, P2, P3) of the operating element (20) are all schematically illustrated in FIG. 5a, and the first position (P1) and the second position (P2) are indicated by dashed lines. On the left side of FIG. 5a, a portion of the front view of the plug connector assembly (100) is shown, and the interaction between the locking element (22) and the relative locking structure (7) is shown.

[0155] In this embodiment, the relative locking structure (7) may be designed as an elastically reversible element that automatically moves to or returns to a non-coupled position (PN) when no force is applied by the locking element (22), for example. In this way, the plug connector can be easily opened by first moving the lever (21) from the second position (P2) to the third position (P3) to disengage the locking element (22) from the relative locking structure (7). Then, when the lever (21) is moved to the first position (P1), the plug connector (1) is separated from the relative plug connector (4) in the opposite direction to the insertion direction (Z).

[0156] The relative locking structure (7) can be made of plastic, for example. It can also be made of metal such as spring steel.

[0157] Alternatively, or additionally, the locking element (22) may be coupled to the relative locking structure (7), for example, through a cam structure or a guide structure, and the relative locking structure (7) may move along a defined path to reach a coupled state (PK) with the locking structure (6). When the plug connector is opened, the relative locking structure (7) may return from the coupled state (PK) to a non-coupled state (PN) along a defined path through a guide structure, a cam structure, or a similar mechanism.

[0158] In this embodiment, the latching hook (9) provided as an example may have a 90° angle or a stepped contour on the contact surface with the locking structure (6) (e.g., without an insertion slope and / or without an extraction slope). This is because such a design does not prevent the locking assembly (30) in this embodiment from simply opening and switching to a non-coupled state (PN). This prevents the locking structure (6) and the relative locking structure (7) from accidentally separating during operation of the plug connector assembly (100), thereby keeping the locking position (PA) particularly secure.

[0159] The cam track (35) of the lever (21) is designed so that the distance between the cam track and the shaft does not change or changes only to a negligible degree while moving from the third position (P3) to the second position (P2). That is, when the lever (21) is rotated from the third position (P3) to the second position (P2), no further relative displacement occurs between the plug connector (1) and the opposing plug connector (4). The cam track design can also be done in other ways, for example, by moving the plug connector (1) slightly away from the opposing plug connector (4) again at the end of the path to control the lock position (PA) more accurately and reliably or to strengthen the locking mechanism.

[0160] Instead of a cam guide on the lever, a rack and pinion design, other power transmission methods, or other gear systems may be considered as alternatives or additionally.

[0161] In another embodiment, alternatively or additionally, when the operating element (20) moves from the third position (P3) to the second position (P2), the locking element (22) may be configured to move toward the relative locking structure (7) in conjunction with the locking structure (6). The considerations (material, elastic properties, guide, shape, etc.) described above for the relative locking structure (7) may also be applied to the locking structure (6).

[0162] Of course, the plug connector assemblies (100) of FIGS. 2a to 4c may also be equipped with an operating element (20) for reducing operating force.

Claims

Claim 1 A plug connector assembly (100) comprising: a plug connector (1) having a plug connector housing (2) having a cable exit section (3); a mating plug connector (4) having a mating plug connector housing (5) and / or mounted on a component housing (81); a locking structure (6) disposed on the plug connector housing (2), preferably on the cable exit section (3); a mating locking structure (7) disposed on the mating plug connector housing (5) and / or the component housing (81); and an elastically reversibly deformable clamping assembly (8), wherein the clamping assembly is particularly -- The above plug connector housing (2) and -- A plug connector assembly (100) disposed between the above-mentioned relative plug connector housing (5) and / or the above-mentioned component housing (81); the locking structure (6) and the relative locking structure (7) are coupled to each other, particularly latching coupled to each other; the locking structure (6) and the relative locking structure (7) can take a locking position (PA) in which they mechanically contact each other in a coupled state, thereby preventing relative movement of the cable exit section (3) with respect to the relative plug connector housing (5) and / or the above-mentioned component housing (81), particularly, and the clamping assembly (8) is elastically deformed in the coupled state (PK) of the locking structure (6) and the relative locking structure (7) to press the locking structure (6) and / or the relative locking structure (7) into the locking position (PA). Claim 2 A plug connector assembly (100) in which, in the combined state of the plug connector (1) and the mating plug connector (4), the locking structure (6) and the mating locking structure (7) are combined with each other. Claim 3 A plug connector assembly (100), wherein, in claim 1 or 2, the locking structure (6) is formed as a latching hook (9), particularly a fixed or elastically reversibly movable latching hook (9), and the relative locking structure (7) is formed as a tab (10) having a latching opening (1), particularly a fixed or elastically reversibly movable tab (10), and / or the relative locking structure (7) is formed as a latching hook (9), particularly a fixed or elastically reversibly movable latching hook (9), and the locking structure (6) is formed as a tab (10) having a latching opening (11), particularly a fixed or elastically reversibly movable tab (10). Claim 4 In any one of claims 1 to 3, the plug connector assembly (100) comprises a plurality of pairs of locking structures (6) and relative locking structures (7). Claim 5 A plug connector assembly (100) wherein, in any one of claims 1 to 4, the clamping assembly (8) comprises a clamping structure (12) and a relative clamping structure (13), the clamping structure (12) is formed elastically and reversibly, and in a combined state (PK) of a locking structure (6) and a relative locking structure (7), the relative clamping structure (13) elastically deforms the clamping structure (12). Claim 6 In claim 5, the clamping structure (12) is disposed in the plug connector housing (2) and the relative clamping structure (13) is disposed in the relative plug connector housing (5) and / or the component housing (81), and / or the relative clamping structure (13) is disposed in the plug connector housing (2) and the clamping structure (12) is disposed in the relative plug connector housing (5) and / or the component housing (81), a plug connector assembly (100). Claim 7 In claim 5 or 6, the clamping structure (12) and / or the relative clamping structure (13) comprises a material selected from the group consisting of rubber, plastic, metal and spring steel, particularly as the main material, a plug connector assembly (100). Claim 8 In any one of claims 5 to 7, the relative clamping structure (13) has a relative clamping structure protrusion (14), particularly a rib (15), protruding toward the clamping structure (12), and the clamping structure (12) has a receiving structure (16) for receiving the relative clamping structure protrusion (14), and in the combined state (PK) of the locking structure (6) and the relative locking structure (7), the relative clamping structure protrusion (14) is received in the receiving structure (16), elastically deforms the clamping structure (12), particularly elastically deforms parallel to the insertion direction (Z) of the plug connector (1) and the relative plug connector (4), and the receiving structure (16) restricts lateral movement of the relative clamping structure protrusion (14), particularly relative movement with respect to the relative plug connector housing (5) and / or the component housing (81) in the transverse direction in the cable discharge direction (K). A limiting plug connector assembly (100). Claim 9 A plug connector assembly (100), wherein in any one of claims 1 to 8 and a second alternative of claim 6, the clamping structure (12) has a clamping structure protrusion (17) protruding toward the plug connector housing (2), and the clamping structure (12) has a deformation element (18) connected to the clamping structure protrusion (17), wherein the deformation element (18) extends substantially laterally with respect to the clamping structure protrusion (17) and is particularly elastically and reversibly deformable, and particularly a cavity (19) is formed between the deformation element (18) and the relative plug connector housing (5) and / or the component housing (81). Claim 10 In claim 9, the deformation element (18) is formed integrally with the clamping structure protrusion (17), or the deformation element (18) is disposed on the clamping structure protrusion (17) in particular non-destructively separable, in a plug connector assembly (100). Claim 11 A plug connector assembly (100), wherein, in any one of claims 1 to 10, the plug connector (1) or the mating plug connector (4) is provided with an operating element (20) movable between a first position (P1) and a second position (P2) to reduce the operating force when coupling the plug connector (1) and the mating plug connector (4), in particular a lever (21) and / or a slider, and the operating element (20) is provided with a locking element (22) configured to cause coupling between the locking structure (6) and the mating locking structure (7) by moving the mating locking structure (7) from a non-coupling position (PN) to a coupling position (PK) in the direction of the locking structure (6) and / or by moving the locking structure (6) from a non-coupling position (PN) to a coupling position (PK) in the direction of the mating locking structure (7). Claim 12 In claim 11, the operating element (20) is configured to combine the plug connector (1) and the counterpart plug connector (4) when moving from the first position (P1) to the second position (P2), and at the third position (P3) located between the first position (P1) and the second position (P2), the insertion process for forming contact between the plug connector (1) and the counterpart plug connector (4) is completed, and when the operating element (20) moves from the third position (P3) to the second position (P2), the locking element (22) To move in the direction of the locking structure (6) in combination with the above relative locking structure (7), and / or A plug connector assembly (100) designed to move in the direction of the relative locking structure (7) in combination with the locking structure (6). Claim 13 A plug connector system (200) comprising: a component (80) having a component housing (81), particularly an inverter (82), a battery, an electric machine, or an electric axle; and a plug connector assembly (100) according to any one of claims 1 to 12, wherein a mating plug connector (4) is mounted on the component housing (81).

Images