Device connector

Abstract

The invention relates to a device connector for a detachable, electrically conductive plug connection, consisting of a plug connector plug and a plug connector mating plug, having a device connector housing in which at least one contact tunnel is formed, wherein the device connector housing has at least one device connector flange for detachable assembly of the device connector with an application housing, wherein the device connector can be formed as a prefabricated application connection in the form of an interface for detachable assembly, with an arrangement consisting of an application housing and at least one high-voltage path.

Description

[0001] March 5, 2026

[0002] -1-

[0003] Description

[0004] Device box

[0005] The invention relates to a device box for a detachable, electrically conductive plug connection, consisting of a plug connector and mating plug connector, comprising a device box housing in which at least one contact tunnel is formed, wherein the device box housing has at least one device box flange for detachably joining the device box with an application housing.

[0006] Contacts generally have at least one electrically conductive contact section for detachable, temporary, or plug-in connection with a corresponding mating contact element, and a shaft section adjoining the contact section for attaching an electrical conductor to the contact. Such a contact, plug-in contact, or high-current contact can be used on a charging plug or socket, for example, for charging an electric vehicle. In this case, a cable is connected to a charging station on one side and carries a connector part in the form of a charging plug on the other, which can be inserted into a corresponding mating connector part in the form of a charging socket on a vehicle to establish an electrical connection between the charging station and the vehicle.

[0007] For contacting or creating detachable, electrically conductive connections, particularly in high-power electrical contacting applications, contact systems have been developed that are based on circular contact geometries for receiving a contact pin, plug-in contact pin, plug stud, contact pin, or ground stud. The starting material consists of a planar contact grid that is hyperbolically twisted into the circular contact geometry. These contact systems, known as RADSOK, are characterized by robust and high-density contact formation due to the substantial contact area with the respective contact pin. Alternatively, instead of the hyperbolic twist, inwardly directed lamellar geometries are known, whose lamellar contact grid is radially symmetrical.

[0008] These contact geometries, preferably used as high-current contact sockets, are known as radial contact sockets or hyperbolic contact sockets, lamellar contact sockets, and are used within RADSOK contact systems. March 5, 2026

[0009] -2-

[0010] RADSOK contact systems of the aforementioned type are received into lamellar contact socket sleeves via their generally cylindrical outer contours and achieve further contact externally via the cylindrical surfaces. Contact systems of this design typically consist of at least one lamellar contact socket and at least one plug-in contact pin.

[0011] In addition to contacting contact elements in the form of contact pins, the lamellar structure of lamellar contact sockets is also used to electrically connect shielding elements within connectors. Shielding elements are often designed as metallic fabric elements that are brought into contact by external lamellar arrangements adjacent to RADSOK contact systems or by lamellar elements inside the connector housing. This complicates the connector housing geometry and simultaneously makes access to the internal contact elements more difficult.

[0012] A wide variety of requirements can be placed on the housing of charging plugs and / or their internal components. These include, for example, protection against external influences, sealing or ventilation measures, cooling, system-dependent geometric designs, accessibility of the current-carrying components, and / or electromagnetic shielding by shielding devices.

[0013] The cooling requirement arises from the fact that heat is generated during the charging process of electrical energy storage devices, such as accumulators, due to the high electrical power and currents transmitted. This heat is not only generated on the cable connecting a charging plug to a charging station, but also on the charging plug itself, and especially on high-current contacts within the charging plug. These contacts establish an electrical connection with corresponding counterparts on the side of a charging socket in an electric vehicle when the charging plug is inserted into the charging socket and electrical power is transmitted.

[0014] As a result of the diverse requirements for connector housings, particularly in high-current applications suitable as charging connectors for battery-electric vehicles, these housings are often elaborately constructed and exhibit a complex geometry, with the components within these housings tending to be difficult to access. March 5, 2026

[0015] -3-

[0016] Supply and charging currents can generally be transmitted as direct currents or alternating currents. Charging currents and high-current applications, especially when using direct current, can have a high current intensity, for example, greater than 200 A, or even greater than 300 A or 350 A, and can lead to heating of the cable as well as any high-current contacts connected to the cable. Supply and charging currents of this type cause increased maintenance and wear on the current-carrying components, potentially requiring their replacement.

[0017] To partially or fully meet the various requirements, similar or identical charging plug housings are often used. Depending on the design, these housings consist of a base housing and, optionally, an additional housing. The base housing is generally designed to be combined with different additional housings or to accommodate various inserts and connector faces. Inserts with connector faces and / or separate connector faces are assemblies comprising various contact elements, cooling devices, and sealing elements. This approach allows for an economical increase in the number of identical parts while simultaneously enabling the implementation of different connector face geometries.

[0018] The aforementioned relationships also apply analogously to charging plug counterparts, which are designed, for example, as inlets or device sockets on the side of a battery-electric vehicle. Accessibility of the device socket's internal components is particularly important for maintenance and replacement purposes.

[0019] In existing detachable connectors with high-voltage connectors, it is necessary to provide access points into the connector opposite or to the side of the plug opening to carry out repairs or replacements. This often requires loosening screws inside the connector housing. Particularly with mating connectors in the form of inlets on a battery-electric vehicle or device, such internal screws may need to be loosened to separate the inlets containing live components from the housing or device socket of the battery-electric vehicle. Such access points are frequently designed as one or more service flaps. This leads to increased labor and can complicate the service process for connectors. (March 5, 2026)

[0020] -4-

[0021] This can lengthen the installation time or increase the likelihood of installation errors. Even more complex from an installation perspective are access options where the entire housing or device box must first be removed to open service hatches.

[0022] The object of the invention is to further develop existing detachable plug connections with high-voltage connectors, so that the aforementioned disadvantages of the prior art are at least partially reduced and the accessibility and / or replaceability of the current-carrying components within the plug connection is improved.

[0023] To solve this problem, the invention proposes a device box, designed as a pre-assembled application connection in the form of an interface, which is detachably connected to a high-voltage path of the application housing of a mating connector. The design of the device box, the application housing, and the high-voltage path is such that, after opening a suitable detachable connection, the device box, as a compact assembly with its components, can be separated from the application housing and the high-voltage path in the opposite direction to the insertion direction of the detachable connector.

[0024] The high-voltage path can be removed from the application housing in the direction of assembly. Press-fit ribs may be provided as a retaining device to prevent the high-voltage path from accidentally falling out after the connection for the device socket has been opened.

[0025] By designing the device box as a pre-assembled unit and by separating the device box assembly from the high-voltage path and the application housing in the opposite direction to the mating of the detachable connector, a replacement concept is provided that allows very simple and service-friendly access to the high-voltage path and the internal components of the connector and supports a simple geometric design of the mating connector (here in the form of an application housing). Since removing or replacing the device box as a unit is only possible by opening the connection technology in a very simple manner, the required labor is minimized. The simplified repair procedure leads to a reduction in production and maintenance costs. March 5, 2026

[0026] -5-

[0027] Particularly in the case of damage to the internal components, seals, shielding, etc. of the connector, or in the case of a new variant of the connector, access from the mating face of the mating connector is made possible by opening the detachable connection technology and removing the device socket in the opposite direction of mating.

[0028] The high-voltage path remains mounted to and attached to the application housing. When installing a new device box assembly, it is simply placed onto the existing high-voltage path and the detachable connection is closed. This eliminates the need for any further work inside the application housing or within the connector. No service access panel or disassembly of the application housing is required for servicing the device box. The high-voltage connection of the high-voltage path remains intact while the device box is disconnected from the high-voltage path and application housing. The use of an HVIL connection (HVIL = High Voltage Interlock) ensures that the electrical system is de-energized during this process.

[0029] According to the invention, the device socket is flanged to the outside of the application housing as a pre-assembled unit. This eliminates the need to open the application housing for replacement or removal of the device socket, thus making the service process safer and avoiding potential hazards. In this particularly service-friendly design, a quick-change concept is enabled in which the device socket is detachably flanged to the application housing as a pre-assembled unit and placed onto the at least one high-voltage path. Both assembly and disassembly of the device socket are facilitated by opening the detachable connection and pulling it off with or against the direction of assembly.

[0030] The invention is explained in more detail below with reference to an exemplary embodiment in conjunction with the figures. These show:

[0031] Fig. 1 shows the front view of an embodiment of the device box as an assembly;

[0032] Fig. 2 shows an exemplary front view of an arrangement of at least one high-voltage path in an application housing; March 5, 2026

[0033] -6-

[0034] Fig. 3 shows the three-dimensional representation of the arrangement of at least one high-voltage path in an application housing;

[0035] Fig. 4 shows the front view of an exploded view of the device box and the arrangement of at least one high-voltage path in an application housing;

[0036] Fig. 5 shows the front view of the device box combined with the arrangement of at least one high-voltage path in an application housing;

[0037] Fig. 6 shows the side view of the device box combined with the arrangement of at least one high-voltage path in an application housing.

[0038] Fig. 1 shows the front view of an embodiment of the device socket 1 as an assembly. The device socket 1 has a housing 3 which forms at least one contact tunnel 4 (the exemplary embodiment shown in Fig. 1 has two contact tunnels 4). The contact tunnel 4 is prismatic, preferably cylindrical, in the axial longitudinal extent of the device socket 1 and can functionally either carry the electrically conductive contact elements of the plug-in contacts or the contact tunnel 4 is part of the electrical connection by means of at least one electrically conductive contact element suitable for electrically contacting both the contact elements of the charging plug and the mating charging plug, for example by means of a lamellar contact socket or plug-in contact pins.

[0039] On the outside of the contact tunnel 4, a further contact element can be provided, for example a lamellar element 5. The lamellar element 5 is designed for electrically conductive contact and can establish an electrically conductive, detachable contact with a suitable plug-in contact element. It is particularly advantageous to use the lamellar element 5 as a contact element for electromagnetic shielding devices.

[0040] The device box housing 3 can be supplemented by a device box flange 2 with a flange contact surface 8 and optionally a gasket (not shown). The flange contact surface 8 is aligned in the mounting direction with the application housing 10, so that the device box 1 can preferably be joined to the application housing 10 on the outside. The mounting direction here corresponds to the mating direction ZR of the plug connection. March 5, 2026

[0041] If electromagnetic shielding is to be implemented or connected ("passed on") within the high-voltage charging plug connection, the device socket 1 can be supplemented with shielding transfer lamellae 6, which are in electrically conductive contact with the at least one lamella element 5. The shielding transfer lamellae 6 are designed to be collapsible with the application housing 10, so that a shielding element of the application housing 10 is connected when collapsible. The arrangement is structurally comparable if a ground connection (earthing) is to be established instead of shielding.

[0042] At least one press rib 7 can be provided on the outside of the device box housing 3, which interacts with the joining geometry of the application housing 10 and, when the connection technology (9, 9', 9") is open, holds the device box 1 in the joined position relative to the application housing 10.

[0043] Fig. 2 shows an exemplary front view of an arrangement of at least one high-voltage path 12 in an application housing 10. In the embodiment shown in Fig. 2, two high-voltage paths 12 are provided. High-voltage paths 12 can be configured in various ways; here, the high-voltage path 12 is represented by an exemplary plug-in contact element 14 that is electrically connected to a busbar 13.

[0044] Fig. 3 shows the three-dimensional front view of the arrangement of at least one high-voltage path 12 in an application housing 10. The high-voltage path(s) 12 are arranged within the application housing 10 such that the plug contact element 14 projects at least partially through a recess 11 from the application housing 10, i.e., extends beyond the outer contour of the application housing 10.

[0045] The recess 11 of the application housing 10 is designed to allow the device box 1 to be joined with the application housing 10 and the at least one high-voltage path 12 in a plug-compatible manner with the device box housing 3 and, if applicable, the device box flange 2.

[0046] Additionally, the recess 11 can be designed to be compatible with the shielding transfer lamellae 6 of the device box 1, so that by joining the device box 1 to the application housing 10 an electrically conductive connection is made, and by pulling the device box 1 away from the application housing 10 a detachable connection is made, for example for the purpose of shielding transfer or grounding. March 5, 2026

[0047] -8-

[0048] Fig. 4 shows the front view of an exploded view of the device box 1 and the arrangement of at least one high-voltage path 12 in an application housing 10. The device box 1 is joined with the application housing 10 and the at least one high-voltage path 12, which is at least partially contained therein, starting from an axially aligned insertion position by insertion in the insertion direction ZR. The components are separated from each other by moving the device box 1 against the insertion direction ZR when the releasable connection technology 9, 9', 9" is opened. In this exemplary embodiment, the releasable connection technology 9, 9', 9" is selected by way of example by a total of four screw connections, each represented by an arrangement consisting of a screw 9, a through-hole 9' in the device box flange 2, and a threaded blind hole 9" in the application housing 10.

[0049] Fig. 5 shows the front view of the device box 1 assembled with the arrangement of at least one high-voltage path 12 in an application housing 10. The detachable connection technology 9, 9', 9" is closed, so that the assembly is fixed and separation of the components 1, 10, 12 is only possible after opening the connection technology 9, 9', 9".

[0050] The shielding transfer lamellae 6 of the device box 1 engage on the inside in the recess 11 of the application housing 10 and thus establish the electrically conductive contact between device box 1 and application housing 10.

[0051] Fig. 6 shows the side view of the device box 1 combined with the arrangement of at least one high-voltage path 12 in an application housing. 10.05. March 2026

[0052] -9-

[0053] Reference symbol list

[0054] 1 device socket

[0055] 2 device box flange

[0056] 3 device box housings

[0057] 4 contact tunnels

[0058] 5 louvered element

[0059] 6 shielding transfer lamellae

[0060] 7 Press rib

[0061] 8 Flange support surface

[0062] 9, 9', 9" detachable connection technology

[0063] 10 application housings

[0064] 11 Exclusion

[0065] 12 High-voltage path

[0066] 13 Power rail

[0067] 14 Plug contact element

[0068] ZR Assembly direction

Claims

March 5, 2026 -1- Claims 1. Device box (1) for a detachable, electrically conductive plug connection, consisting of a plug connector and mating plug connector, comprising a device box housing (3) in which at least one contact tunnel (4) is formed, wherein the device box housing (3) has at least one device box flange (2) for detachably joining the device box (1) with an application housing (10), characterized in that the device box (1) is designed as a pre-assembled application connection in the form of an interface for detachably joining an arrangement consisting of an application housing (10) and at least one high-voltage path (12).

2. Device box (1) according to claim 1, characterized in that the at least one contacting tunnel (4) is designed as a cylindrical through-bore, so that plug contact elements of the connector plug and / or the connector mating plug can be inserted and / or inserted through the contacting tunnel (4).

3. Device box (1) according to claim 1, characterized in that the at least one contacting tunnel (4) has an electrically conductive contact element into which the plug contact elements of the connector plug and / or the connector mating plug can be inserted and detachably electrically contacted with each other.

4. Device box (1) according to claim 1, characterized in that the at least one contacting tunnel (4) has at least one lamellar element (5) on its outside.

5. Device box (1) according to claim 1, characterized in that the device box housing (3) has shielding transfer fins (6).

6. Device box (1) according to claims 4 and 5, characterized in that the at least one lamellar element (5) and the shielding transfer lamellae (6) are electrically conductively contacted with each other. March 5, 2026 -2- 7. Device box (1) according to claim 5, characterized in that the shielding transition lamellae (6) are designed such that they are electrically conductively contacted with the arrangement consisting of application housing (10) and at least one high-voltage path (12) with a recess (11) of the application housing (10) when the device box (1) is folded.

8. Device box (1) according to claim 1, characterized in that the device box housing (3) has at least one press rib (7).

9. Device box (1) according to claim 1, characterized in that the device box (1), assembled with an arrangement consisting of application housing (10) and at least one high-voltage path (12), rests at least partially on the outer surface of the application housing (10) and projects at least partially into a recess (11) of the application housing (10).

10. Device box (1) according to claim 1, characterized in that the device box (1) rests on the outside of the application housing (10) with a flange support surface (8) of the device box flange (2).

11. Device box (1) according to claim 1, characterized in that the at least one contact tunnel (4) is formed by a first and at least one second contact tunnel (4) such that the device box (1) is suitable for a double plug connection.

12. Device box (1) according to claim 1, characterized in that the device box (1), assembled with an arrangement consisting of application housing (10) and at least one high-voltage path (12), is held in the assembled position by a detachable connection technology (9, 9', 9").

Images