Plug connector

Abstract

The present disclosure relates to a plug connector (1) for connecting a conductor (2) of an electrical cable (3). The plug connector (1) extends along a longitudinal axis (x) and comprises a connector element (4) for establishing an electrical connection with a mating connector element (5). The connector element (4) extends along the longitudinal axis (x) and comprises at a dorsal end (6) a receiving section (7), which is designed as a tubular collar (8) for receiving an end section (9) of the conductor (2), and at a distal end (10) a contact section (11), which comprises a receiving space (12) for receiving the mating connector element (5) and an elastic contact element (13) being arranged at the contact section (11). The receiving section (7) is configured to connect the therein arranged end section (9) of the conductor (2) to the connector element (4). The elastic contact element (13) is configured to establish an electrical connection to the mating connector element (5) in a connected state. The present disclosure further relates to a cable assembly, a mating connector and a power distribution assembly.

Description

[0001] Plug Connector

[0002] FIELD OF THE DISCLOSURE

[0003] The present disclosure relates to a plug connector, a cable assembly, a mating connector and a power distribution assembly for high voltage applications.

[0004] BACKGROUND OF THE DISCLOSURE

[0005] DE102019209436A1 published on 31.12.2020 in the name of Robert Bosch GmbH relates to a plug connector for plugging together along an insertion direction with a mating plug connector. The plug connector has a housing with at least one contact chamber, which is arranged in the housing and is designed to receive a contact element. The contact chamber has a first opening and at least one second opening. A primary locking element for the contact element, which can be accommodated in the contact chamber, can be inserted into the first opening. A secondary locking element for the contact element, which can be accommodated in the contact chamber, can be inserted into the second opening. When the primary locking element is inserted into the first opening, and when the secondary locking element is inserted into the second opening, an outer side of the wall is protected against electrical arcing from the interior of the contact chamber along a direction of rotation around the insertion direction.

[0006] DE202014102609U1 published on 10.09.2015 in the name of Leoni Bordnetz Sys. GmbH relates to a high-voltage distributor box for a motor vehicle, which has a housing with a lower part, which can be closed by a cover and on the outside of which a plurality of housing-side plug parts are formed for connecting a respective electrical high-voltage line with the aid of a line-side plug part. An electrical monitoring loop is formed for detecting a fault situation, in which the two plug parts are separated from one another, a breaker which is assigned to each housing-side plug part and the breakers being connected to one another in series via the monitoring loop, the breakers interrupting the monitoring loop in the event of the fault situation, with the monitoring loop running exclusively along an outer side of the housing.

[0007] SUMMARY OF THE DISCLOSURE

[0008] Until now, amongst electric vehicles, electric heavy-duty vehicles, particularly electric trucks, have served niche applications such as milk floats, pushback tugs and forklifts, typically using lead-acid batteries. But the rapid development of lighter and more energy dense battery chemistries in the 21 st century has extended the range of applications for electric drive to trucks in many more roles. Until now, amongst electric vehicles, long-haul freight has been the segment of trucking least suited to electrification, as the increased weight of batteries relative to fuel reduces payload capacity and the alternative of more frequent recharging reduces delivery time. In contrast, urban short-haul delivery has been rapidly electrified because the clean and quiet nature of electric trucks fits well with urban planning and municipal regulations and the capacities of reasonably sized batteries are well suited to the daily stop-and-go traffic of a metropolitan area. This also reduces noise and pollution compared to internal combustion trucks. Going electric is therefore the current goal of many original equipment manufacturers (OEMs) in the automotive industry, particularly in the heavy-duty vehicle sector. However, the design of electric vehicles, in particular for heavy-duty vehicle architectures, poses new challenges for OEM engineering departments. In particular, size and weight must be reduced, while at the same time accommodating the necessary equipment, including battery packs, distribution units and high-voltage cabling. The increased number of battery packs and power consumables requires more cable connections, making efficient routing a major challenge.

[0009] Engineers designing electrical systems for electrical vehicles (EVs) and in particular for heavy-duty electrical vehicles are looking for flexible and modular solutions that can be configured in a variety of ways and ensure ease of assembly and maintenance. This is in line with technological trends observed in the market, where OEMs tend to centralize key functions of the electrical system, while looking for simple and modular means of power distribution and ways to reduce the amount of wiring. When defining their high-voltage architecture, EV OEMs continue to look for different technical solutions to distribute power throughout the vehicle, from the power sources (chargers, batteries) to the engines. With the trend towards centralization of power distribution unit (PDU) functions, there is a need to apply multiple routes of cables.

[0010] An objective of the present disclosure can therefore be seen in improving the power distribution with a reduction in the total number of cables and flexibility in the routing of the connections. A plug connector according to the present disclosure, for connecting a conductor of an electrical cable, extends along a longitudinal axis. The plug connector typically comprises a connector element for establishing an electrical connection with a mating connector element, which connector element extends along the longitudinal axis. The connector element typically comprises at a dorsal end a receiving section, which is designed as a tubular collar for receiving an end section of the conductor and at a distal end a contact section, which comprises an elastic contact element, which is arranged at the contact section. The distal end of the connector element is thereby usually the end facing the end of the plug connector which is foreseen for connecting the plug connector with a mating plug connector. The dorsal end usually faces the end of the plug connector, which is interconnected to the electrical cable. The receiving section of the connector element is configured to connect the therein arranged end section of the conductor to the connector element and the elastic contact element. The tubular collar is configured to establish the electrical connection of the connector element to the mating connector element in a connected state.

[0011] In an alternative embodiment of the plug connector according to the present disclosure, the distal end comprises a contact section with an elastic receiving space or a receiving space comprising elastic contact elements, like spring fingers or the like. For connecting a conductor of an electrical cable, the plug connector extends along the longitudinal axis and may comprise a connector element for establishing an electrical connection with a mating connector element. The connector element may extend along the longitudinal axis and comprise at a dorsal end a receiving section, which is designed as a tubular collar for receiving an end section of the conductor and at a distal end a contact section, which comprises a receiving space. The tubular collar may be configured to connect the therein arranged end section of the conductor to the connector element which is configured to establish the electrical connection of the connector element to the mating connector element in a connected state. The contact section may be designed adjacent to the receiving space as an elastic contact element, e.g. in form of spring fingers which can be preloaded and are radially deflected during mating.

[0012] These designs are in line with technological trends observed in the market, where OEMs tend to centralize key functions of the electrical system, while looking for simple and modular means of power distribution and ways to reduce the amount of wiring. The plug connectors according to the present disclosure enable simple and reliable routing of electrical cables. Especially for high-voltage automotive architectures in VCB (Voltage Class B) above 60 VDC, typically between 500 VDC and 2000V DC, preferably between 750 VDC and 1500 VDC, such as 1000 VDC, the plug connector can be used together with cables to distribute power throughout the vehicle, from the power sources (chargers, batteries) to the engines. The plug connector according to the present disclosure makes it possible to establish a reliable electrical connection even under dynamic load, e.g. due to vibrations due to the elastic contact element and is at the same time easy and fast to assemble or disassemble.

[0013] The tubular collar can be designed as a cylindrical sleeve, which is typically made form a ductile metallic material, which is electrically conductive and can be plastically deformed by a shaping process. The tubular collar can be attached to the therein arranged end section of the conductor by a force-fit connection or by a bonded connection. The tubular collar can for example be crimped to the therein arranged end section of the conductor. By the crimp connection, the end section of the conductor is electrically and mechanically attached to the connector element. Particularly good results can be achieved when the crimping is done by electromagnetic pulse crimping. Electromagnetic pulse crimping offers the advantage of a particularly uniform plastic deformation / attachment in circumferential direction of the tubular collar. As an alternative, also welding is possible, such as high current welding.

[0014] By attaching the conductor to the plug connector, a cable assembly is formed. A cable assembly according to the present disclosure typically comprises a plug connector according to the present disclosure and an electrical cable, comprising the conductor which is electrically connected to the plug connector. The plug connector is typically configured for high voltages, such as above 60 VDC, preferably between 500 VDC and 2000 VDC, more preferably between 750 VDC and 1500 VDC, such as 1000 VDC. High voltages allow the transmission of electrical power at low currents. In the present application the cable assembly is capable of transmitting several hundred Amperes to be compliant with ISO 19642-9 class D, published in 01 -2019. This allows to avoid the need of providing a cooled cable, which simplifies the construction. The electrical cable typically comprises at least one strand, a cable braiding encompassing the at least one strand and a cable jacket encompassing the cable braiding. The cable braiding can be in form of a polymer layer or in form of a metal mesh.

[0015] The conductor may have a cross-sectional area between 15 mm2and 250 mm2, more preferably between 25 mm2and 200 mm2, most preferably between 35 mm2and 150 mm2. To allow tighter bending radiuses and reducing the diameter of the overall electrical cable, the conductor of the electrical cable may comprise at least two strands, which are stranded with each other in a helical manner. Also cables with 3, 4 or 5 strands are possible.

[0016] For connecting the cable assembly via the plug connector, the plug connector comprises a contact section as described above noted already. For establishing a reliable electrical connection even under dynamic load, e.g. due to vibrations, an elastic contact element is arranged in the contact section in the receiving space. The contact section may be designed as a tubular collar and the receiving space may be designed as an annular receiving space at an inner surface of the tubular collar, with the elastic contact element being arranged in the annular receiving space. Depending on the design, the annular receiving space may be designed as a circumferential groove for receiving the elastic contact element. The elastic contact element can be in the form of a spring element, which is arranged within a receiving space of the contact section. The spring element can be in form of a number of individual spring clips, e.g. in form of C-clips which are each arranged in an individual groove of the annular receiving space or in form of e.g. a lamellar, louver or wavy spring element. Alternatively, the spring element can be barrel shaped, or one or several ring shaped coil springs, known as canted coil springs, can be used. The barrel shaped spring element can extend along the longitudinal axis and comprise at both ends with respect to the longitudinal axis two at least partially circumferential bridges and several spring elements extending between and interconnecting the two bridges. The spring elements can be deflected away from the longitudinal axis or be deflected towards the longitudinal axis. The receiving section and the contact section can be made as two individual parts or be made in an integral manner, preferably merging into each other. Alternatively or in addition, the receiving section and the contact section of the connector element may be separated by a partition wall. The partition wall may function as a stop for the end section of the electrical cable and assure the correct positioning of the electrical cable with respect to the connector element. A pin may be arranged in the partition wall and protrude into the contact section. The pin can be formed integral with the partition wall and fulfill the function of protecting the operator from touching the live parts of the plug connector.

[0017] Alternatively, the pin can be arranged in an opening of the partition wall and be at least partially made from an electrically isolating material or compromise a cap made from an electrically isolating material. The pin may be made one-pieced and entirely made form an electrically isolating material and therefore serve the purpose of centering the plug connector with respect to a mating plug connector during mating, to protect an operator from coming into contact with the inside of the connector element. When the pin is made as a one-pieced part, which is arranged in the opening of the partition wall, it can be clipped into the opening during assembly.

[0018] The plug connector may comprise a voltage protection means, which at least partially covers the outer surface of the connector element to protect an operator during handling of the plug connector. This ensures that the operator does not come in contact with the connector element when connecting or disconnecting the plug connector. The voltage protection means may be designed as a tubular sleeve, which extends at least partially from the distal end to the dorsal end of the connector element and preferably comprises adjacent to the distal end a protruding collar. The sleeve thereby usually covers essentially the entire connector element on its outer shell surface. The protruding collar may provide additional protection for the operator, by ensuring that the operator does not accidentally reach into the plug connector. The voltage protection means may be attached to the connector element by a press fit or secured in place with connection elements, e.g. in form of snap fingers or latching lugs.

[0019] A sealing element, also referred to as socket sealing, can be arranged adjacent to the dorsal end of the connector element. The sealing element may comprise a corrugated surface, which is configured to be in contact with the voltage protection means and / or the conductor. The sealing element can be in form of a ring. The shell surfaces facing the conductor and / or the voltage protection means can comprise a corrugated surface, which has a threaded or wavy cross section. The sealing element can be arranged on the shell surface of the conductor. The sealing element is typically arranged between the conductor and the voltage protection means. The corrugated surface serves the purpose of increasing the surface area of the sealing element and to avoid or at least significantly mitigate leakage, in particular electrical creepage over the insulating surface. Leakage is the gradual transfer of electrical energy across a boundary normally viewed as insulating, in this case the voltage protection means.

[0020] The voltage protection means is typically made from an impact-resistant plastic material, e.g. made of a polyamide. The sealing element is preferably made from an elastic and a non-conductive plastic material, e.g. silicone. The voltage protection means may comprise attachment means in form of snap fingers. The snap fingers may in the mounted state of the voltage protection means engage in a groove of the connector element to secure the voltage protection means in place and prevent slippage.

[0021] The voltage protection means may comprise at least one keying element which can comprise at least one groove or tongue. The keying element allows for a faster and safer connection, as incompatible connections cannot be established. Good results can be achieved, with the at least one groove or tongue being arranged radially on an outer surface of the voltage protection means, oriented parallel to the longitudinal axis and being configured to interact with a corresponding tongue or groove of a mating connector. Alternatively, also at least one helical groove or tongue on the outer surface of the voltage protection means is possible. Nevertheless, a groove or tongue oriented parallel to the longitudinal axis is preferred, as such a design avoids that the plug connector with a thereto typically attached electrical cable needs to be rotated, which could cause undesired torsions onto the cable assembly.

[0022] The plug connector may comprise a cable gland for establishing a strain relieved connection of the electrical cable. The cable gland typically comprises a first annular base element, which is configured to be connected to the electrical cable in a strain-relieved manner. The first annular base element may comprise a first crimp neck for attaching the first annular base element to a cable jacket of the electrical cable. The first annular base element may also comprise a second crimp neck for attaching the first annular base element to a cable braiding of the electrical cable. The first annular base element can be in form of an essentially cylindrical sleeve, which comprises a stop. The stop may be in form of an annular collar, which is arranged on the outer shell surface of the first annular base element.

[0023] The cable gland can comprise a second annular base element for connecting the plug connector to a housing or a mating connector. The cable gland can further comprise a gland nut for connecting the first annular base element to the second annular base element and thereby interconnecting the electrical cable to the housing or a mating connector in a strain-relived manner. The second annular base element may comprise a first threaded neck for screwing the second annular base element to the housing or the mating connector and a second threaded neck for receiving the gland nut. In the mounted position of the first annular base element the stop of the first annular base element typically comes into contact with the second annular base element. The first annular base element can comprise a sealing means, e.g. in form of a sealing ring, which seals the first annular base element with respect to the second annular base element.

[0024] The second annular base element can be in form of an essentially cylindrical sleeve, which comprises a stop. In a mounted position of the second annular base element, the stop comes into contact with the housing or the stop of a cable gland of a mating electrical cable. The stop can comprise a sealing means, e.g. in form of a sealing ring, which seals the second base element with respect to the housing or the stop of the cable gland of the mating electrical cable. The stop may be in form of an annular collar, which is arranged on the outer shell surface of the second annular base element. In the mounted state of the cable gland, the gland nut positions the first annular base element with respect to the second annular base element. The gland nut can position the annular base elements with respect to each other by bringing the stop of the first annular base element in contact with an end stop arranged at the second threaded neck of the second annular base element. The cable gland may alternatively comprise a flange for interconnecting the plug connector to a housing or a mating connector. This allows that the cable gland can be attached to a housing with at least one screw in a fast and reliable manner.

[0025] The cable assembly may form part of a cabling system of an electrical vehicle and may be provided as part of a power distribution assembly. A power distribution assembly according to the present disclosure typically comprises a cable assembly and a connection and / or distribution element, which comprises the mating connector element for electrically connecting the cable assembly. The mating connector element can be a one-pieced cable connector. The mating connector element is typically made form a conductive metallic material. The mating connector element may comprise a contact pin, which is configured to establish the electrical connection to the connector element of the cable assembly. The distal end of the contact pin may comprise a protection cap which is made from an isolating material. The distal end is hereby the end facing the plug connector. The connection and / or distribution element can comprise at least two mating connector elements to connect the cable assembly to another cable assembly.

[0026] The present disclosure further relates to a mating connector for establishing an electrical connection with a plug connector or a cable assembly, preferably a plug connector or a cable assembly as described above noted. The mating connector can be arranged within a power distribution assembly as described below noted in more detail. Alternatively, the mating connector can be attached to a wall of a housing and serve as an adapter for connecting a plug connector or a cable assembly to another cable or electrical installation. The mating connector typically has a longitudinal axis and comprises a mating connector element, which is configured to establish an electrical connection to the connector element of a plug connector and extends along the longitudinal axis. The mating connector element may comprise a contact pin, which comprises a first end for connecting to a connector element of a plug connector. The first end is typically designed as a cylindrical sleeve, configured to receive the at least one elastic contact element of the contact section. The first end can additionally comprise a bore, for receiving the pin of the plug connector. The contact pin further typically comprises a second end, which can comprise a receiving section. The receiving section can be a tubular collar for receiving an end section of a conductor or can alternatively be a contact tab. This allows to connect the contact pin to a conductor or alternatively to a connection element via a screw connection. The mating connector element is typically at least partially a rotational symmetrical part, allowing for easy and efficient machining. The mating connector element may be a massive pin, allowing the transmission of high currents.

[0027] The mating connector further typically comprises a tubular isolation element, which is interconnected to the mating connector element and also extends along the longitudinal axis. The tubular isolation element extends from a proximal end to a distal end and preferably at least partially encompasses the mating connector element and electrically shields the mating connector element in a connected state. The tubular isolation element can be in form of a cylindrical sleeve, which is made from an impact resistant polymer. The tubular isolation element may at the proximal end encompass the mating connector element and at the distal end comprise a mechanical interface. The mechanical interface is typically foreseen for interconnecting the mating connector to a housing or a plug connector. The mechanical interface may therefore comprise an annular base element for connecting the mating connector element to the housing or the plug connector. Besides insulating the mating connector element from the mechanical interface, the tubular isolation element may further serve for aligning the mating connector element with respect to the connector element of the plug connector.

[0028] The tubular isolation element can interconnect the mating connector element to the mechanical interface in an electrically isolated manner. The tubular isolation element may comprise at least one keying element which comprises at least one groove or a tongue. The at least one groove or tongue may be arranged radially on an inner surface of the tubular isolation element, oriented parallel to the longitudinal axis and typically being configured to interact with a corresponding tongue or groove of a plug connector.

[0029] The mating connector can comprise control contacts which are configured to interact with an electrical bridge of a plug connector, which in a connected state together close an electrical circuit. To allow for an assembly with several cable connections, the keying element of each tubular isolation element can be arranged radially on the inner surface of the tubular isolation element with a particular angle with respect to the control contacts. This way, non-matching cable connections can be avoided. This can avoid system failure and electrical shorts. In use, the purpose of the power distribution assembly is typically, besides distributing the power amongst at least three cable assemblies via the mating connector element, to also form a so-called “black box”. Black box is to be understood in the context of the present disclosure as a self-contained assembly, which is not be opened by unauthorized personal or to be sealed in a manner that it cannot be opened non-destructively. The power distribution assembly can compromise a housing, which encompasses the connection and / or distribution element, with the connection and / or distribution element being arranged in the housing in an electrically isolated manner with respect to the housing.

[0030] The housing may comprise a simple design, essentially comprising a casing with a top and a bottom cover. With few housing elements it is possible to connect a number of cable assemblies, even cable assemblies with conductors having varying cross sections. To form a self-contained assembly, the casing and covers can be screwed together. To form an assembly which cannot be opened without destruction, the housing elements can be welded or glued together.

[0031] The housing can have different shapes, with a scalable number of side walls. This provides a possibility to flexibly route the wiring harness’ outlets in various directions. As mentioned before, the power distribution assembly can be considered as a “black box”, since the operator does not need to open it, to connect a cable assembly. The housing can be rectangular with a number of individual connection and / or distribution elements, which each connecting a first incoming cable assembly to a second outgoing cable assembly. Alternatively, also a polygonal housing is possible to connect several cable assemblies to each other. The connection and / or distribution element arranged in the housing can thereby have a number of contact pins for connecting a number of cable assemblies with each other, in particular also an uneven number of cable assemblies.

[0032] The connection and / or distribution element can be arranged on a mount, which is at least partially encompassed by an insulating element, also referred to as terminal insulator, to prevent an operator during handling of the plug connector from touching the connection and / or distribution element. The mount and the insulating element can be made integral with each other. The mount and the insulating element are typically made from an electrically isolating material. The mount can be in form of a post, comprising a plug connection for receiving the connection and / or distribution element. The insulating element may be designed as a shell, comprising a recess for receiving the plug connector.

[0033] The connection and / or distribution element, can be encompassed by an insulating element within the housing, which insulating element may be formed by an upper shell and a lower shell. The upper shell and the lower shell may together form an enclosure for the connection and / or distribution element. To attach the insulating element in a secure position with respect to the housing, the insulating element may comprise tongues. The tongues can extend radially away from the insulating element and form a snap connection with the housing. The housing can comprise recesses, which are foreseen to receive the tongues of the insulating element.

[0034] The upper and lower shell may each comprise a mount with a male or female connection means for forming a connection with a mating connection means of the connection and / or distribution element. The upper and lower shell may further comprise a circumferential wall, from which the tongues protrude radially away. The upper and lower shell can each also comprise anti-rotation means, which prevent the upper and lower shell from rotating with respect to the housing.

[0035] The power distribution assembly can comprise a cable gland with the cable assembly being connected to the power distribution assembly by the plug connector for establishing a strain relieved connection of the cable assembly with the power distribution assembly.

[0036] The power distribution assembly may comprise connection means for connecting the power distribution assembly to another power distribution assembly. This can be realized by various connection means, e.g. by screwing. The modular design of the power distribution assembly simplifies the installation process, as the cable assemblies can be connected to the connection and / or distribution element either before or after it is fitted to the vehicle chassis. This is also an advantage when servicing the system over its lifetime - a single damaged cable assembly can be replaced without having to replace the whole system. A simple routing of different phases or polarities of the electrical system can be achieved by stacking at least two power distribution assemblies to each other.

[0037] The plug connector and / or the cable assembly and / or the power distribution assembly is typically used in automotive applications, in particular for heavy duty vehicles. The cable assembly can be used for transmitting electrical power from battery packs to the engine of the vehicle. Alternatively, as electrification is an inevitable trend, the plug connector and / or the cable assembly can also be used in future on board Megawatt Charging Systems or supporting vehicle’s functionality as distributed energy resource, e.g. for vehicle to grid solutions (V2G).

[0038] A method for assembling the power distribution assembly typically comprises at least the following steps:

[0039] - Providing a power distribution assembly according to the present disclosure;

[0040] - Providing at least two cable assemblies according to the present disclosure;

[0041] - Plugging the plug connector to the connection and / or distribution element within the power distribution assembly, wherein the electrical connection is secured by the elastic contact element;

[0042] - Preferably attaching the plug connector to the housing of the power distribution assembly by the cable gland, by securing the first annular base element with respect to the second annular base element by the gland nut.

[0043] It is to be understood that both the foregoing general description and the following detailed description present embodiments, and are intended to provide an overview or framework for understanding the nature and character of the disclosure. The accompanying drawings are included to provide a further understanding, and are incorporated into and constitute a part of this specification. The drawings illustrate various embodiments, and together with the description serve to explain the principles and operation of the concepts disclosed. BRIEF DESCRIPTION OF THE DRAWINGS

[0044] The herein described disclosure will be more fully understood from the detailed description given herein below and the accompanying drawings which should not be considered limiting to the disclosure described in the appended claims. The drawings are showing:

[0045] Fig. 1 A perspective view from the top onto a first variation of the power distribution assembly with the cover being unfolded;

[0046] Fig. 2 A perspective view from the front and above onto a first variation of the cable assembly in partially sectional view; Fig. 3 A perspective view from the front and above onto the cable assembly according to Figure 2 in partially sectional and exploded view;

[0047] Fig. 4 A detail view of the cable assembly according to Figure 3;

[0048] Fig. 5 A perspective view from the front and above onto the cable assembly according to Figure 2 in partially sectional and exploded view; Fig. 6 A detail view of the cable assembly according to Figure 5;

[0049] Fig. 7 A perspective view from the top onto the mating connector element and cable assemblies of the power distribution assembly according to Figure 1 ; Fig. 8 A perspective view from the top onto the power distribution assembly according to Figure 1 while connecting a cable assembly to the mating connector element;

[0050] Fig. 9 A perspective view from the top onto the power distribution assembly according to Figure 9 while connecting the cable assembly to the power distribution assembly via the cable gland;

[0051] Fig. 10 A perspective view from the top onto the power distribution assembly according to Figure 1 in the assembled state;

[0052] Fig. 11 A perspective view from the top onto a second variation of the power distribution assembly in Fig. 11a, in a partially sectional view in Fig. 11 b and a detail view thereof in Fig. 11 c;

[0053] Fig. 12 A perspective view from the top onto the second variation of the power distribution assembly according to Fig. 11 with the cover being unfolded;

[0054] Fig. 13 A perspective view from the top onto the mating connector element and cable assemblies of the power distribution assembly according to Figure 11 ;

[0055] Fig. 14 A perspective view from the front and above onto a second variation of the cable assembly in Fig. 14a, in a partially sectional view in Fig. 14b and a detail view thereof in Fig. 14c; Fig. 15 A perspective view from the back and above onto a third variation of the cable assembly with a thereto connected mating connector;

[0056] Fig. 16 A perspective view from the back and above onto the third variation of the cable assembly and mating connector according to Figure 15 in a partially sectional and exploded view;

[0057] Fig. 17 A perspective view from the back and above onto a fourth variation of the cable assembly with thereto connected mating connector;

[0058] Fig. 18 A perspective view from the back and above onto the fourth variation of the cable assembly and mating connector according to Figure 17 in a partially sectional and exploded view;

[0059] Fig. 19 A perspective view from the back and above onto a mating connector in a partially sectional and exploded view;

[0060] Fig. 20 A rear view onto the mating connector element according to Figure 19 in Figure 20a and the voltage protection means of the cable assembly according to Figure 18 in Figure 20b with corresponding keying elements.

[0061] DESCRIPTION OF THE EMBODIMENTS

[0062] Reference will now be made in detail to certain embodiments, examples of which are illustrated in the accompanying drawings, in which some, but not all features are shown. Indeed, embodiments disclosed herein may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Whenever possible, like reference numbers will be used to refer to like components or parts.

[0063] Figure 1 shows a first variation of the power distribution assembly 40 with the cover 46 being unfolded. The depicted power distribution assembly 40 comprises three cable assemblies 38, 38’, 38” and a connection and / or distribution element 41 . The connection and / or distribution element 41 comprises in the shown variation three mating connector elements 5, shown in more detail in Figures 7 to 10, for electrically connecting the shown cable assemblies 38, 38’, 38” to each other. The shown mating connector elements 5 each comprise a contact pin, which is configured to establish the electrical connection to the plug connectors 1 , T, 1 ” of the cable assemblies 38, 38’, 38”. The depicted power distribution assembly 40 compromises a polygonal housing 29, which encompasses the connection and / or distribution element 41. The connection and / or distribution element 41 is arranged in the housing 29 in an isolated manner with respect to the housing 29 on a mount 43.

[0064] Figure 2 shows a first variation of the cable assembly 38 in partially sectional view. The depicted plug connector 1 for connecting the conductor 2, typically in from of a cable strand 39, of the electrical cable 3 extends along a longitudinal axis x and comprises a connector element 4 for establishing an electrical connection with a mating connector element. The connector element 4 in the depicted variation is designed as an essentially cylindrical sleeve, which also extends along the longitudinal axis x. The connector element 4 comprises at its dorsal end 6 a receiving section 7, which is designed as a tubular collar 8 for receiving an end section 9 of the conductor 2. At the distal end 10, the connector element 5 comprises a contact section 11 , which comprises a receiving space 12 and an elastic contact element 13, which is arranged within the receiving space 12. The conductor 2 is attached to the connector element 5 within the receiving section 7 by crimping the tubular collar 8 to the conductor 2 and thereby connecting the therein arranged end section 9 of the conductor 2 to the connector element 4. The contact section 11 comprises an elastic contact element in the form of a spring element 14, which establishes the electrical connection between the plug connector and a mating plug connector.

[0065] Figure 3 and 4 show the cable assembly 38 according to Figure 2 in partially sectional and exploded view in Figure 3 and a detailed view thereof in Figure 4. The cable assembly 38 comprises the plug connector 1 and the thereto attached electrical cable 3, which comprises a conductor 2. The conductor 2 is encompassed by a cable jacket 35. As can be obtained from the two figures, the contact section 11 is designed as a tubular collar 15 and the receiving space 12 is designed as an annular receiving space at an inner surface 16 of the tubular collar 15 with the elastic contact element 13 being arranged in the annular receiving space 12. The depicted plug connector 1 comprises a voltage protection means 17, which covers the outer surface 18 of the connector element 4 to protect an operator during handling of the plug connector 1 .

[0066] The depicted voltage protection means 17 is designed as a tubular sleeve 19 which extends from the distal end 10 to the dorsal end 6 of the connector element 4 and comprises adjacent to the distal end 10 a protruding collar 20. A sealing element 21 , in the depicted variation in form of an annular ring, is arranged adjacent to the dorsal end 6 of the connector element 4. The sealing element 21 comprises a corrugated surface 22, which is configured to be in contact with the voltage protection means 17 and the conductor 2. In the depicted variation the sealing element 21 has a corrugated surface 22 on both shell surfaces, the one facing the conductor 2 and the one facing the voltage protection means 17.

[0067] As can be obtained best from Figure 4, the receiving section 7 and the contact section 11 of the depicted variation of the connector element 4 are separated by a partition wall 23. A pin 24 is arranged in the partition wall 23 and protrudes into the contact section 11 . The pin 24 is arranged in an opening 25 of the partition wall 23 and is at least partially made from an electrically isolating material or compromises a cap 26 made from an electrically isolating material. The depicted pin 24 fulfills the function to protect the operator from touching the live parts of the plug connector.

[0068] Figure 5 and 6 show the cable assembly 38 according to Figure 2 in a partially sectional and exploded view in Figure 5 and a detailed view thereof in Figure 6. The depicted plug connector 1 comprises a cable gland 27 for establishing a strain relieved connection of the electrical cable 3. The cable gland 27 comprises a first annular base element 28 to be connected to the electrical cable 3 in a strain-relieved manner and a second annular base element 30 for connecting the plug connector 1 to a housing or a mating connector. The depicted gland nut 31 is foreseen for connecting the first annular base element 28 to the second annular base element 30 and thereby interconnecting the electrical cable 3 to the housing or a mating connector in a strain-relived manner. The second annular base element 30 comprises a first threaded neck 32 (threads not shown) for screwing the second annular base element 30 to the housing or the mating connector and a second threaded neck 33 (threads not shown) for receiving the gland nut 31 . The first annular base element 28 comprises a first crimp neck 34 for attaching the first annular base element 28 to a cable jacket 35 of the electrical cable 3 and a second crimp neck 36 for attaching the first annular base element 28 to a cable braiding 37 of the electrical cable 3.

[0069] Figures 7 to 10 show the assembly of a variation of the power distribution assembly 40.

[0070] Figure 7 shows the internal components of the power distribution assembly 40 within the housing, which is on purpose not shown in Figure 7. The depicted power distribution assembly 40 comprises three cable assemblies 38, 38’, 38” and a connection and / or distribution element 41 . The depicted one-pieced connection and / or distribution element 41 comprises three mating connector elements 5, 5’, 5” for electrically connecting the cable assemblies 38, 38’, 38” to each other. The depicted connection and / or distribution element 41 is arranged on a mount 43 within the housing. The depicted mount is partially encompassed by a insulating element 44 to prevent an operator during handling of the plug connector 1 from touching the connection and / or distribution element 41. The insulating element 44 can comprise two half-shells, which together encapsulate the connection and / or distribution element 41 or just comprise a single shell. Figure 8 shows the power distribution assembly 40 while connecting a cable assembly 38’ to the mating connector element 5. The power distribution assembly 40 comprises a housing 29, which encompasses the connection and / or distribution element 41 , with the connection and / or distribution element 41 being arranged in the housing 29 in an isolated manner with respect to the housing 29. The cable assembly 38’ is inserted into the housing 29 through an opening in the wall of the housing 29 and to be mated with the contact pin 42 of the mating connector element 5, which is configured to establish the electrical connection to the connector element 4 of the cable assembly 38’. The second annular base element 28 is screwed to the housing 29 by the first threaded neck. The second threaded neck 33 is foreseen for receiving the gland nut 31 . The first annular base element 30 is already attached to the preassembled cable assembly 38’ via the first crimp neck 34 and the second crimp neck 36.

[0071] Figure 9 shows screwing the gland nut 31 onto the second annular base element

[0072] 28 and thereby attaching the first annular base element 30 by clamping the first annular base element 30 between second annular base element 28 and gland nut 31 . Figure 10 shows a perspective view from the top onto the power distribution assembly according to Figure 1 in the assembled state. The shown housing

[0073] 29 comprises a polygonal casing 47, covered by an upper and lower cover 46. In the assembled state, the casing 47 together with the upper and lower cover 46 encapsulates the connection between the plug connectors 1 , T, 1 ” and the mating plug connectors. Figure 11 shows a second variation of the power distribution assembly 40. As can be obtained best from Figure 11a, the shown variation of the power distribution assembly 40 comprises a housing 29, which is formed by a casing 47 and two covers 46, 46’. The housing 29 comprises connection means 45 for attaching the entire power distribution assembly 40 to an external structure, e.g. to a chassis of an electric vehicle, in particular to the frame of a truck. As can be obtained best from Figure 11b and Figure 11c, the housing 29 of the second variation also houses a connection and / or distribution element 41 , which itself is encompassed by a insulating element 44 within the housing 29. The insulating element 44 is formed by an upper shell 50 and a lower shell 50’, which together form an enclosure for the connection and / or distribution element 41 , as will be described in more detail with regard to Figure 12 and Figure 13. To attach the insulating element 44 in a secure position with respect to the housing 29, the shown variation of the insulating element 41 comprises tongues 48, 48’. These tongues 48, 48’ extend radially away from the insulating element 44 and form a snap connection with the housing 29. The housing 29 comprises recesses 49, 49’, which are foreseen to receive the tongues 48, 48’ of the insulating element 44.

[0074] The second variation of the power distribution assembly 40 with the upper cover 46 being unfolded is shown in Figure 12. Figure 13 shows the mating connector element 5 and cable assemblies 38, 38’, 38” of the power distribution assembly 41 in more detail. The insulating element 44 is formed by the upper shell 50 and lower 50’ shell, which together form an enclosure for the connection and / or distribution element 41. The upper shell 50 and lower shell 50’ each comprise a mount 43 with a male or female connection means 45 for forming a connection with a mating connection means 45’ of the connection and / or distribution element 41 . The upper shell 50 and lower shell 50’ further comprise a circumferential wall 51 , from which the tongues 48, 48’ protrude radially away. The upper shell 50 and lower shell 50’ shell also comprise anti-rotation means, which prevent the upper shell 50 and lower shell 50’ from rotating with respect to the housing 29.

[0075] Figures 14a-c shows a second variation of the cable assembly 38. The basic design of the shown second variation of the cable assembly 38 differs from the first variation of the cable assembly in the design of the voltage protection means 17, the pin 24 as well as the elastic contact element 13.

[0076] As can be obtained best from Figure 14c, the shown voltage protection means 17 comprise attachment means in form of snap fingers 52. The snap fingers 52 engage in the mounted state of the voltage protection means 17 in a groove 53 of the connector element 4 to secure the voltage protection means 17 in place and prevent slippage. To also protect an operator from coming into contact with the inside of the connector element 4, a pin 24 is arranged within the connector element 4. The shown pin 24 is made as a one-pieced part, which is arranged in an opening 25 of the partition wall 23. The shown pin 24 is during assembly clipped into the opening 25. The shown variation of the elastic contact element 13 is in form of two canted coil springs. The coil springs are each arranged within a receiving space 12, 12’ within the connector element 4.

[0077] Figures 15 and 16 show a perspective view from the back and above onto a third variation of the cable assembly 38 and a mating connector 59. Figure 15 shows the cable assembly 38 with thereto connected mating connector 59 in a con- nected state. The shown mating connector 59 establishes an electrical connection with the shown cable assembly 38. The mating connector 59 has a longitudinal axis x and comprises a mating connector element 5, which is configured to establish an electrical connection to the connector element of the plug connector 1 and extends along the longitudinal axis x. The shown mating connector 59 further comprises a tubular isolation element 60, which also extends along the longitudinal axis x and is at a proximal end connected to the mating connector element 5 and at a distal end connected to a mechanical interface 61 . The tubular isolation element 60 at least partially encompasses the mating connector element 5 and electrically shields the mating connector element 5 in a connected state. The shown plug connector 1 comprises a cable gland 27 with a flange 58, for interconnecting the plug connector 1 to a housing (not shown).

[0078] As shown by Figure 16, the plug connector 1 comprises an electrical bridge 68, which in the connected state closes an electrical circuit with the control contacts 67 of the mating connector 59. The mating connector 59 comprises a mechanical interface 61 for interconnecting the mating connector 59 to the shown plug connector 1. Therefore, the mechanical interface 61 comprises an annular base element 62 for mechanically connecting the mating connector element 5 to the plug connector 1 . In the shown embodiment, the tubular isolation element 60 interconnects the mating connector element 5 to the mechanical interface 61 in an electrically isolated manner. The tubular isolation element 60 comprises at its distal end tongues 70, which engage in recesses 71 of the annular base element 62. At its dorsal end, the tubular isolation element 60 comprises a bead 72, which encompasses the mating connector element 5 and abuts against a stop 73. The shown mating connector element 5 further comprises a recess for the pin 24 of the plug connector 1 , as well as a cap, functioning as a voltage protection means. As can be further obtained, the tubular isolation element 60 comprises a keying element 54, which comprises a groove 55. The shown groove 55 is arranged radially on the inner surface 63 of the tubular isolation element 60, oriented parallel to the longitudinal axis x and configured to interact with a corresponding tongue of the plug connector 1 .

[0079] Figures 17 and 18 show a perspective view from the back and above onto a fourth variation of the cable assembly 38 with thereto connected mating connector 59 in Figure 17 and in a partially sectional and exploded view in Figure 18. The shown embodiment is essentially the same as the embodiment shown by Figures 15 and 16. The major difference is the design of the mating connector element 5. The mating connector element 5 shown in Figure 16 comprises a contact pin 42 which comprises a first end 64 for connecting to a connector element 4 of a plug connector 1 and a second end 65, which comprises a receiving section 66, which is a tubular collar for receiving an end section of a conductor. The mating connector element 5 shown by Figure 18 comprises a contact pin 42 which comprises a first end 64 for connecting to a connector element 4 of the plug connector 1 and a second end 65, which comprises a contact tab 74 with a bore, for attaching the mating connector 59 to an external component via a screw.

[0080] Figure 19 shows a perspective view from the back and above onto a mating connector 59 in a partially sectional and exploded view. The shown tubular isolation element 60 comprises at its distal end tongues 70, which engage in recesses 71 of the annular base element 62. At its dorsal end, the tubular isolation element 60 comprises a bead 72, which encompasses the mating connector element 5 and abuts against a stop 73. The shown mating connector element 5 further comprises a recess for a pin of a plug connector, as well as a cap, functioning as a voltage protection means. As can be further obtained, the tubular isolation element 60 comprises a keying element 54 which comprises a groove 55. The shown groove 55 is arranged radially on the inner surface 63 of the tubular isolation element 60, oriented parallel to the longitudinal axis x and configured to interact with a corresponding tongue of a plug connector. The tubular isolation element 60 further comprises control contacts 67, which in the connected state close an electrical circuit with an electrical bridge 68 of a plug connector. Figure 20a shows a rear view onto the mating connector element 59 according to Figure 19. Figure 20b shows the voltage protection means 17 of the cable assembly with corresponding keying elements 54. As can be obtained from Figure 20b, the voltage protection means 17 comprises a guiding rib 69 as well as a tongue 56, which is part of the keying element 54. The tubular isolation element 60 shown in Figure 20a comprises a groove 55, which corresponds to the tongue

[0081] 56 of the voltage protection means 17.

[0082] Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the Spirit and scope of the disclosure. LIST OF DESIGNATIONS

[0083] 1 Plug connector 18 Outer surface

[0084] 2 Conductor (connector element)

[0085] 3 Electrical cable 19 Tubular sleeve

[0086] 4 Connector element 20 Collar (Voltage protection

[0087] 5 Mating connector element 30 means)

[0088] 6 Dorsal end 21 Sealing element

[0089] (receiving section) 22 Corrugated surface

[0090] 7 Receiving section 23 Partition wall

[0091] 8 Tubular collar 24 Pin

[0092] (receiving section) 35 25 Opening

[0093] 9 End section 26 Cap

[0094] (conductor) 27 Cable gland

[0095] 10 Distal end 28 First annular base ele¬

[0096] (contact section) ment

[0097] 11 Contact section 40 29 Housing

[0098] 12 Receiving space 30 Second annular base ele¬

[0099] (contact section) ment

[0100] 13 Elastic contact element 31 Gland nut

[0101] 14 Spring element 32 First threaded neck

[0102] 15 Tubular collar 45 33 Second threaded neck

[0103] (contact section) 34 First crimp neck

[0104] 16 Inner surface 35 Cable jacket

[0105] (tubular collar) 36 Second crimp neck

[0106] 17 Voltage protection means 37 Cable braiding 38 Cable assembly 57 Outer surface (Voltage

[0107] 39 Strand 25 protection means)

[0108] (electrical cable) 58 Flange (Cable gland)

[0109] 40 Power distribution assem- 59 Mating connector bly 60 Tubular isolation element

[0110] 41 Connection / distribution 61 Mechanical interface element 30 62 Annular base element

[0111] 42 Contact pin (mating con(Mechanical interface) nector element) 63 Inner surface (Tubular

[0112] 43 Mount isolation element)

[0113] 44 Insulating element 64 First end (Contact pin)

[0114] 45 Connection means 35 65 First end (Contact pin)

[0115] 46 Cover (Housing) 66 Receiving section

[0116] 47 Casing 67 Control contacts

[0117] 48 Tongue 68 Electrical bridge

[0118] 49 Recess (Housing) 69 Guiding rib

[0119] 50 Shell (insulating element) 40 70 Tongue (tubular isolation

[0120] 51 Wall element)

[0121] 52 Snap fingers 71 Recess (annular base el¬

[0122] 53 Groove ement)

[0123] 54 Keying element 72 Bead

[0124] 55 Groove (Keying element) 45 73 Stop

[0125] 56 Tongue (Keying element) 74 Contact tab

[0126] X Longitudinal axis

Claims

PATENT CLAIMS1. A plug connector (1 ) for connecting a conductor (2) of an electrical cable (3), which plug connector (1 ) extends along a longitudinal axis (x) and comprises a connector element (4) for establishing an electrical connection with a mating connector element (5), which connector element (4) extends along the longitudinal axis (x) and comprises i. at a dorsal end (6) a receiving section (7), which is designed as a tubular collar (8) for receiving an end section (9) of the conductor (2), and ii. at a distal end (10) a contact section (11 ), which comprises an elastic contact element (13), which is arranged at the contact section (11 ), wherein the receiving section (7) is configured to connect the therein arranged end section (9) of the conductor (2) to the connector element (4) and the elastic contact element (13) is configured to establish an electrical connection of the connector element (4) to the mating connector element (5) in a connected state.

2. The plug connector (1 ) according to claim 1 , wherein the elastic contact element (13) is in the form of a spring element, which is arranged within a receiving space (12) of the contact section (11 ).

3. The plug connector (1 ) according to claim 1 or 2, wherein the contact section (11 ) is designed as a tubular collar (15) and the receiving space (12) is designed as an annular receiving space at an inner surface (16) of the tubular collar (15) with the elastic contact element (13) being arranged in the annular receiving space (12).

4. The plug connector (1 ) according to one of the preceding claims, wherein the tubular collar (8) is configured to be crimped to the therein arranged end section (9) of the conductor (2).

5. The plug connector (1 ) according to one of the preceding claims, wherein the plug connector (1 ) comprises a voltage protection means (17) at least partially covering an outer surface (18) of the connector element (4) to protect an operator during handling of the plug connector (1 ).

6. The plug connector (1 ) according to claim 5, wherein the voltage protection means (17) is designed as a tubular sleeve (19) which extends at least from the distal end (10) to the dorsal end (6) of the connector element (4) and preferably comprises adjacent to the distal end (10) a protruding collar (20).

7. The plug connector (1 ) according to claim 5 or 6, wherein a sealing element (21 ) is arranged adjacent to the dorsal end (6) of the connector element (4) which sealing element (21 ) comprises a corrugated surface (22) which is configured to be in contact with the voltage protection means (17) and the conductor (2).

8. The plug connector (1 ) according to one of claims 5 to 7, wherein the voltage protection means (17) comprises at least one keying element (54), which comprises at least one groove (55) or tongue (56).

9. The plug connector (1 ) according to claim 8, wherein the at least one groove (55) or tongue (56) is arranged radially on an outer surface (57) of the voltage protection means (17), oriented parallel to the longitudinal axis (x) and configured to interact with a corresponding tongue (56) or groove (55) of the mating connector (59).

10. The plug connector (1 ) according to one of the preceding claims, wherein the plug connector (1 ) is configured for high voltages above 60 VDC, preferably between 500 VDC and 2000 VDC, more preferably between 750 VDC and 1500 VDC, such as 1000 VDC.11 . The plug connector (1 ) according to one of the preceding claims, wherein the receiving section (7) and the contact section (11 ) of the connector element (4) are separated by a partition wall (23).

12. The plug connector (1 ) according to claim 11 , wherein a pin (24) is arranged in the partition wall (23) and protrudes into the contact section (11 ).

13. The plug connector (1 ) according to claim 12, wherein the pin (24) is arranged in an opening (25) of the partition wall (23) and is at least partially made from an electrically isolating material or compromises a cap (26) made from an electrically isolating material.

14. The plug connector (1 ) according to one of the preceding claims, wherein the plug connector (1 ) comprises a cable gland (27) for establishing a strain relieved connection of the electrical cable (3), comprising a first annular base element (28), configured to be connected to the electrical cable (3) in a strain-relieved manner.

15. The plug connector (1 ) according to claim 14, wherein the first annular base element (28) comprises a first crimp neck (34) for attaching the first annular base element (28) to a cable jacket (35) of the electrical cable (3) and a second crimp neck (36) for attaching the first annular base element (28) to a cable braiding (37) of the electrical cable (3).

16. The plug connector (1 ) according to claim 14 or 15, wherein the cable gland (27) comprises a second annular base element (30) for connecting the plug connector (1 ) to a housing (29) or the mating connector (59) and a gland nut (31 ) for connecting the first annular base element (28) to the second annular base element (30) and thereby interconnecting the electrical cable (3) to the housing (29) or the mating connector (59) in a strain-relived manner.

17. The plug connector (1 ) according to claim 16, wherein the second annular base element (30) comprises a first threaded neck (32) for screwing the second annular base element (30) to the housing (29) or the mating connector (59) and a second threaded neck (33) for receiving the gland nut18. The plug connector (1 ) according to one of claims 14 or 15, wherein the cable gland (27) comprises a flange (58) for interconnecting the plug connector (1 ) to a housing (29) or the mating connector (59).

19. A cable assembly (38) comprising a plug connector (1 ) according to one of the preceding claims and an electrical cable (3) comprising the conductor (2) which conductor is electrically connected to the plug connector (1 ), in particular a conductor (2) with a cross-sectional area between 15 mm2and 250 mm2, more preferably between 25 mm2and 200 mm2, most preferably between 35 mm2and 150 mm2.

20. The cable assembly (38) according to claim 19, wherein the conductor (2) of the electrical cable (3) comprises at least two strands (39) which are stranded with each other in a helical manner.21 . A mating connector (59) for establishing an electrical connection with a plug connector (1 ) or a cable assembly (38), preferably a plug connector (1 ) according to one of claims 1 to 18 or a cable assembly (38) according to one of claims 19 or 20, the mating connector (59) having a longitudinal axis (x) and comprising: a. a mating connector element (5), which is configured to establish an electrical connection to the connector element (4) of the plug connector (1 ) and extends along the longitudinal axis (x);b. a tubular isolation element (60) which is interconnected to the mating connector element (5) and also extends along the longitudinal axis (x), wherein the tubular isolation element (60) at least partially encompasses the mating connector element (5) and electrically shields the mating connector element (5) in a connected state.

22. The mating connector (59) according to claim 21 , wherein the mating connector (59) comprises a mechanical interface (61 ) for interconnecting the mating connector (59) to a housing (29) or a plug connector (1 ).

23. The mating connector (59) according to claim 22, wherein the mechanical interface (61 ) comprises an annular base element (62) for connecting the mating connector element (5) to the housing (29) or the plug connector (1 ).

24. The mating connector (59) according to claim 22 or 23, wherein the tubular isolation element (60) interconnects the mating connector element (5) to the mechanical interface (61 ) in an electrically isolated manner.

25. The mating connector (59) according to one of claims 21 to 24, wherein the tubular isolation element (60) comprises at least one keying element (54) which comprises at least one groove (55) or tongue (56).

26. The mating connector (59) according to claim 25, wherein the at least one groove (55) or tongue (56) is arranged radially on an inner surface (63) of the tubular isolation element (60), oriented parallel to the longitudinal axis(x) and configured to interact with a corresponding tongue (56) or groove(55) of a plug connector (1 ).

27. The mating connector (59) according to one of claims 21 to 26, wherein the mating connector element (5) comprises a contact pin (42) which comprises a. a first end (64) for connecting to a connector element (4) of a plug connector (1 ) and b. a second end (65) which comprises a receiving section (66), which is a tubular collar for receiving an end section of a conductor or a contact tab.

28. The mating connector (59) according to one of claims 21 to 27, wherein the mating connector (59) comprises control contacts (67) which are configured to interact with an electrical bridge (68) of a plug connector (1 ), which in a connected state together close an electrical circuit.

29. Power distribution assembly (40) comprising a cable assembly (38) according to one of claims 19 or 20 and a connection and / or distribution element (41 ), which comprises the mating connector element (5) for electrically connecting the cable assembly (38).

30. The power distribution assembly (40) according to claim 29, wherein the mating connector element (5) comprises a contact pin (42), which is configured to establish the electrical connection to the connector element (4) of the cable assembly (38).

31. The power distribution assembly (40) according to claim 30, wherein the connection and / or distribution element (41 ) comprises at least two mating connector elements (5) to connect the cable assembly (38) to another cable assembly (38’).

32. The power distribution assembly (40) according to one of claims 29 to 31 , wherein the power distribution assembly (40) compromises a housing (29), which encompasses the connection and / or distribution element (41 ), with the connection and / or distribution element (41 ) being arranged in the housing (29) in an isolated manner with respect to the housing (29).

33. The power distribution assembly (40) according to one of claim 29 to 32, wherein the connection and / or distribution element (41 ), is arranged on a mount (43), which is at least partially encompassed by an insulating element (44) to prevent an operator during handling of the plug connector (1 ) from touching the connection and / or distribution element (41 ).

34. The power distribution assembly (40) according to one of claims 29 to 33, comprising a plug connector (1 ) according to one of claims 12 to 15, wherein the cable assembly (38) is connected to the power distribution assembly (40) by a cable gland (27) for establishing a strain relieved connection of the cable assembly (38) with the power distribution assembly (40).

35. The power distribution assembly (40) according to one of claims 29 to 34, wherein the power distribution assembly (40) comprises connection means(45) for connecting the power distribution assembly (40) to another power distribution assembly (40’).

36. The power distribution assembly (40) according to one of claims 29 to 35, wherein the power distribution assembly (40) forms a self-contained as- sembly, which is sealed in a manner that it cannot be opened non-destruc- tively.

37. Use of the plug connector (1 ) according to one of claims 1 to 18 and / or the cable assembly (38) according to one of claims 19 or 20 and / or the mating connector (59) according to one of claims 21 to 28 and / or the power distribution assembly (40) according to claims 29 to 36 in automotive applications, in particular for heavy duty vehicles.

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