Plug connector distributor

Abstract

The invention relates to a plug connector (S), in particular for an arrangement having a wiring harness and a plurality of devices (A, B, C, D), wherein the wiring harness has a plurality of plug connectors (S), at least one, which are connected to one another via cables (3), wherein devices (A, B, C, D) can be connected to one another via the wiring harness. According to the invention, the at least one plug connector (S) takes the form of a plug connector distributor (1). A distributor (16) is arranged in the plug connector distributor (1) in such a way that a distributor function can be incorporated into the plug connector distributor (1) and at least two cables (3) are connected to one another via the at least one distributor element (16) in order to implement the distributor function. The distributor element (16) can be a busbar and consist, for example, of a metal sheet. The plug connector distributor (1) can also take the form of a multi-way distributor.

Description

[0001] Connector distributor

[0002] Description

[0003] The invention relates to a connector distributor and a cable set with such a connector distributor according to the features of the preamble of claim 1. In particular, the invention relates to a high-voltage connector with a distributor function.

[0004] Cable sets are known that have several connectors which are interconnected via cables, and which connect devices such as actuators, sensors, control units, power supplies and the like via these cable sets.

[0005] DE 41 38 714 AI discloses a wiring harness for the vehicle electrical system of a motor vehicle. This harness is characterized by the fact that it is completely prefabricated and easy to handle.

[0006] According to DE 10 2005 012 077 A1, wiring harnesses in the form of round cables are used in motor vehicles. The wiring harness proposed in the disclosure is an integrated wiring harness comprising at least two printed circuit board circuits.

[0007] German patent DE 10 2013 015 957 A1 describes a wiring harness that allows for customized configuration, as it can be assembled from individual modules and thus adapted to the specific vehicle and its component configuration. A wiring harness known internally to the applicant is shown in Figures 5 and 9. This harness consists of several connectors S, which are interconnected by cables and connected to devices A to D. Devices B and C are connected to device A via a distributor Y. Devices B and C are supplied to device A via the distributor Y. The distributor Y is an additional component in the wiring harness. The distributor Y is necessary to connect the connectors S of devices B and C to the connector of device A.In this distributor, the two cables each (a total of four cables) from the two connected connectors S are combined, and only two cables are then routed from distributor Y to the connector of device A. Figure 9 shows the internal structure of a known connector S, which is used in the wiring harness according to Figure 5 (to be explained later).

[0008] In practice, for example in a vehicle, several high-voltage auxiliary units are often supplied from a single power source. This usually requires one or more distributors integrated into the wiring harness. Distributors are separate components that, in addition to the connectors, must be placed within the wiring harness's installation space and are assembled with individual parts.

[0009] A distributor for a connection system for charging electric and hybrid vehicles is described in DE 10 2022 119 534 A1. The distributor of the connection system is to be improved and simplified. Instead of the known ultrasonic welding, a pluggable system is used. Each connector has, on the one hand, at least one crimp area that can be connected to an electrical conductor or stranded wire, and on the other hand, two pin contacts or two socket contacts that are in turn connected to electrical distributors. These also have crimp areas for the electrical distributor conductors to be connected. A power distributor with fuses connected to the wiring harness, especially for power distribution within the electrical system of a motor vehicle, is disclosed in DE 10 2007 018 175 A1.The plan is to provide a power distribution unit that simplifies manufacturing and assembly and reduces the space required.

[0010] The invention is based on the objective of simplifying a wiring harness with the aim of reducing the required space compared to conventional wiring harnesses.

[0011] This problem is solved by the features of claim 1. Advantageous embodiments are found in the dependent claims.

[0012] According to the invention, it is provided that one or more distributors can be dispensed with or that one or more distributors are no longer required (see curly bracket Figure 5).

[0013] According to the invention, this idea is implemented by designing and enabling a connector of the wiring harness to be connected to at least one device as well as to at least one other connector, thus eliminating the need for a distributor. This advantageously eliminates the need for a distributor, as its distribution function can be realized through appropriate measures or components within the connector or connector distributor according to the invention.

[0014] The invention extends, for example, a high-voltage connector, such as a socket connector, with a distribution function. This distribution function can also include a multi-distribution function. In this way, auxiliary components can be supplied with power via a cable run from connector or connector distributor to connector.

[0015] In a further development of the invention, one or more conductors or cables can be additionally integrated into a conductor assembly of the connector distributor. An electrical connection is made between the conductors and the high-voltage contact by means of an electrical connecting element. Within the inventive connector or connector distributor, for example, two conductors and the high-voltage contact can be connected to each other by means of a distributor or connecting element, thus distributing the current. The remaining individual parts of the connector are adapted, and functional synergies are utilized without significantly impacting the installation space.

[0016] The high-voltage connector distributor can also be designed as a multi-connector distributor. In this case, more than two cables, for example six, can exit the connector distributor. This makes it possible for one connector distributor to supply several devices (simultaneously).

[0017] In a further development of the invention, the distribution or connecting element is designed in the form of a distribution or connecting rail. In its simplest embodiment, this rail can, for example, consist of a sheet metal part.

[0018] In a further development of the invention, it is provided that the connector distributor according to the invention can be integrated into the existing installation space of a conventional connector. The width and height of the connector distributor are identical to those of a conventional connector. As a result of the inventive idea, the connector components themselves can be extended using the connector distributor according to the invention. Furthermore, a reduction in the number of components in the wiring harness becomes possible, since one (or more) separate distributors can be dispensed with. An increase in current-carrying capacity is a further advantage. Another important aspect is the possibility of automated assembly of the connector distributor according to the invention.

[0019] For added safety, a CPA (Connector Position Assurance) can be used to secure the position of the connector hub. It is understood that the use of a CPA is optional. A CPA is generally a mechanism that ensures a pair of mated connectors remains connected after mating. This type of locking mechanism secures the connection in the mated position.

[0020] A high-voltage interlock (HVIL) is, in practice, one of the safety features of hybrid and fully electric vehicles designed to protect people. The interlock acts as a type of circuit breaker, sending an alarm or fault code if a high-voltage connector in the assembled plug-in connection becomes loose, disconnects, or is damaged during operation (such as while driving, during maintenance, while parked, etc.). However, the use of an interlock in this form is optional.

[0021] A connector distributor according to the invention is proposed, which can be integrated into a cable set with, for example, several connectors interconnected by cables. Devices such as actuators, sensors, control units, power supplies, and the like can be connected to one another via the cable set. The connector distributor is characterized by being designed as a connector with a distribution function. Furthermore, the connector distributor is suitable for being connected to at least one device and at least one other connector.

[0022] Furthermore, an arrangement with a cable set and several devices is proposed, wherein at least one connector of the cable set is designed as a connector distributor. The cable set, for example, has several connectors that can be interconnected via cables. Devices can be connected to one another via the cable set. These devices can be, for example, actuators, sensors, control units, power supplies, and the like. The connector distributor according to the invention is suitable for being connected in a cable set to at least one device as well as to at least one further connector.

[0023] An embodiment of such a connector with a distribution function (therefore referred to as a connector distributor) and a cable set in which such a connector distributor is used are described below and illustrated with reference to the figures.

[0024] Figure 1 shows an external connector distributor according to the invention, which has a housing into which, for example, four cables are inserted or protrude from it.

[0025] Figure 2 shows the connector distributor according to the invention as shown in Figure 1 in a schematic sectional view. Figure 3 shows a housing of the connector distributor according to the invention with its individual essential components in a schematic representation.

[0026] Figure 4 shows an exploded view of the essential elements arranged within the housing according to Figure 3.

[0027] Figure 5 shows, as already described at the beginning, a wiring harness with several connectors that are interconnected via cables and to which devices A to D are connected. Devices B and C are connected to device A via a distributor Y.

[0028] Figure 6 shows a wiring harness, also with several connectors, but without the distributor.

[0029] Figure 7 shows a side view and Figure 8 a top view of the housing (schematic representation) of the connector distributor according to the invention.

[0030] Figure 9 shows an exploded view of the essential elements arranged within the connector shown in Figure 5.

[0031] Figure 10 shows, as in Figure 4, the essential elements of the connector distributor according to the invention in an exploded view to clearly illustrate the differences.

[0032] Figure 11 shows a schematic sectional view of the possibility of creating a multi-connector according to the connector distributor according to the invention. Figure 1 shows an external view of a connector distributor 1 according to the invention. The connector distributor 1 according to the invention has a housing 2, which consists, for example, of two housing parts 2.1, 2.2 for receiving, for example, two cable assemblies 20 (Figure 4) of the (plugged / paired) connector distributor 1. For example, four cables 3 are inserted into or protrude from the housing 2. A CPA (Connector Position Assurance) is indicated by 4, which ensures that the (paired) connector distributor 1 remains connected after the cable assemblies 20 are plugged together. Alternatively, more or fewer than the four cables 3 shown in this embodiment can be used.

[0033] As shown more clearly in Figure 3, the CPA 4 preferably has a clamp-like shape, allowing it to be slid onto the rear area of ​​the two housing parts 2.1 and 2.2 from above. The use of a CPA 4 is optional if its function is desired and can also be achieved by alternative means.

[0034] Retaining caps for receiving the line seals 5 of the line assemblies 20 are marked with the reference numeral 6. These can be locked to the front area of ​​the housing 2 or to the housing parts 2.1, 2.2. The retaining caps 6 are preferably divided into an upper and a lower retaining cap 6.1, 6.2 (Figure 3).

[0035] Figure 2 shows a schematic sectional view of the connector distributor 1 from Figure 1. Reference numeral 9 denotes a retaining ring, and reference numeral 13 denotes an HCT4 contact. The retaining ring 9 is integrated into the lower part of the housing 2. The schematically depicted HCT4 contact 13 extends to a contact carrier upper part 10 within the housing 2 of the connector distributor 1. The HCT4 contact 13 is supported by a contact carrier lower part 11 (Figure 4). A high voltage is supplied to the connector distributor 1 via the HCT4 contact 13. The HCT4 contact 13 is then electrically connected, for example, to a cable 3. At least two cables 3 are electrically connected to each other via an electrical distributor 16. In its simplest form, the distributor 16 is a busbar, for example, a sheet metal plate, to implement the distribution function.Contact 13 is specifically referred to by the applicant as HCT4 contact. However, it can also be referred to by other names.

[0036] Figure 3 shows the connector distributor 1 with the two retaining caps 6.1 and 6.2, as well as with the retaining ring 9 and a seal 8. Pins 7 protrude from the bottom of the housing 2. The inner contour of the retaining caps 6.1 and 6.2 together replicates the shape of the cable seal 5. Cable seals 5 of the cable assembly(s) 20 can be inserted into or received by these.

[0037] Figure 4 shows an exploded view of the internal structure of a cable assembly 20 of the connector distributor 1. The cable assembly 20 essentially consists of a contact carrier upper part 10, a contact carrier lower part 11, the HCT4 contact 13, a right shielding plate 14, and a left shielding plate 15. The contact carrier lower part 11 carries the HCT4 contact 13 and is anchored in a position holder 12.

[0038] Figure 4 shows two cables 3 that are held and routed within the cable seal 5. However, the embodiment is not limited to two cables 3. Two strain reliefs 17 and two crimp sleeves 18 are also provided around the cables 3, the function of which is self-explanatory.

[0039] A key difference from conventional connectors S lies in the integration of the distributor 16 into the connector distributor 1. The two cables 3 are electrically connected to this distributor 16 during the assembly of the cable assembly 20. One of the cables 3 can connect to the distributor 16 in the upper area, and the other in the lower area.

[0040] Figure 6 shows a cable set, also with several connectors S, but without the distributor Y. The function of the distributor according to Figure 5 is taken over by a connector distributor (SV) 1 designed according to the invention, which is plugged into device B, for example. The cables of the connector of device C are fed to the connector distributor 1. Devices B and C are now connected to device A via the connector distributor 1. This maintains the basic functionality of the cable set shown in Figure 5. However, the additional distributor Y is omitted.

[0041] Figure 7 shows a schematic side view and Figure 8 a schematic top view of the housing 2 of the connector distributor 1, which is plugged into, for example, the device B (Figure 6). It can be seen that this connector distributor 1, with its distribution function, is identical in size and geometric design to the connector S according to Figure 5, which is also plugged into the device B there. The connector distributor 1 according to the invention can therefore directly replace the connector S according to Figure 5, despite its integrated distribution function. Only the direction of the cable exit may differ slightly.

[0042] Figure 9 shows essential parts (schematically) of the internal components (or a power assembly) of a known connector S (assembled), which is used in the wiring harness according to Figure 5. Essential components are the position holder 12, the contact carrier lower part 12 with HCT4 contact 13, the shielding elements 14, 15, and the contact carrier upper part 10. The HCT4 cable 13 is electrically connected to the cable 3. A strain relief 17 is attached around the cable 3, and the cable 3 is secured in a crimp sleeve 18 and passed through the cable seal 5.

[0043] Figure 10 shows the essential parts (exploded view) of the internal structure of the connector distributor 1 with distribution function according to the invention. It can be seen that at least two cables 3 are connected to each other via the at least one busbar or the at least one distributor 16 in order to implement the distribution function (see Figure 4).

[0044] Figure 11 shows the internal structure of the finished connector distributor 1 after the internal components, as shown in Figure 10, have been inserted into the housing 2 of the connector distributor 1. Arrow 19 also indicates a variant that can modify the connector distributor 1 into a multi-connector (not shown in detail). Thus, for example, six wires or cables can exit the connector distributor 1. Such a connector distributor 1 can then supply several devices A, B, C, and D.

[0045] A connector S, designed according to the invention as a connector distributor 1, is described. A distributor 16 is arranged in the connector distributor 1 such that a distribution function can be incorporated into the connector distributor 1, wherein at least two cables 3 are connected to each other via the at least one distributor element 16 in order to realize the distribution function. The distributor element 16 can be a busbar and, for example, consist of a sheet metal part. The connector distributor 1 can also be designed as a multi-connector distributor.

[0046] The connector distributor 1 according to the invention is particularly intended for an arrangement with a cable set and several devices A, B, C, D, wherein the cable set has several connectors S, at least one, which are interconnected via cables 3. Devices A, B, C, D can be interconnected via the cable set. At least one connector distributor 1 according to the invention is provided in the cable set.

[0047] The connector distributor 1 shown and described here is a 90° 2-pin socket connector with a distributor function. This represents only one of several possible designs and applications and is not to be defined as limiting.

[0048] Reference symbol list

[0049] A, B, C, D devices, actuators, sensors, control units, power supply, etc.

[0050] S connectors

[0051] Y distributor

[0052] Connector distributor (SV)

[0053] Housing of 1; 2.1, 2.2 Housing half of 2

[0054] Line, cable

[0055] CPA (optional, also known as backup)

[0056] Pipe seal

[0057] Retaining caps; 6.1 upper retaining cap, 6.2 lower retaining cap

[0058] Splints

[0059] Seal (especially designed as a radial seal)

[0060] retaining ring

[0061] Contact carrier top

[0062] Contact carrier base

[0063] Position holder

[0064] HCT4 contact (commonly referred to as high-voltage contact)

[0065] Umbrella element; umbrella plate, right

[0066] Umbrella element; umbrella plate, left

[0067] Distribution board, distribution rail; busbar

[0068] Strain relief

[0069] Crimp sleeve

[0070] Arrow

[0071] Cable assembly

Claims

Connector distributor Patent claims 1. Connectors (S), in particular for an arrangement with a cable set and several devices (A, B, C, D), wherein the cable set has several connectors (S), at least one, which are connected to each other via cables (3), wherein devices (A, B, C, D) can be connected to each other via the cable set, characterized in that at least one connector (S) is designed as a connector distributor (1 ).

2. Connector distributor (1) according to claim 1 , characterized in that a distributor (16) is arranged in the connector distributor (1 ) such that a distributor function can be incorporated into the connector distributor (1).

3. Connector distributor (1 ) according to claim 1 or 2, characterized in that at least two cables (3) are connected to each other via at least one distributor element (16) in order to realize the distributor function, 4. Connector distributor (1 ) according to claim 3, characterized in that the distributor element (16) is a busbar and can be made of a sheet metal part.

5. Connector distributor (1) according to one of claims 1 to 4, characterized in that one or more cables (3) can additionally be integrated into a cable assembly (20) of the connector distributor (1).

6. Connector distributor (1 ) according to one of claims 1 to 5, characterized in that the connector distributor (1) is designed as a multiple distributor.

7. Connector distributor (1) according to one of claims 1 to 6, characterized in that a CPA (4) can optionally be used.

8. Connector distributor (1) according to one of claims 1 to 7, characterized in that an HVIL can optionally be used.

9. Arrangement with a wiring harness and several devices (A, B, C, D), wherein the wiring harness has several connectors (S) which can be interconnected via cables (3), wherein devices (A, B, C, D) can be interconnected via the wiring harness, characterized in that at least one connector (S) of the wiring harness is designed as a connector distributor (1 ).

10. Arrangement according to claim 9, characterized in that the connector distributor (1) is suitable for being connected to at least one device (A, B, C, D) as well as to at least one further connector (S).

Images