CN115051190A

CN115051190A - Plug device

Info

Publication number: CN115051190A
Application number: CN202210219073.4A
Authority: CN
Inventors: R·莫利托; D·埃哈德; J·默斯勒
Original assignee: Robert Bosch GmbH
Current assignee: Robert Bosch GmbH
Priority date: 2021-03-08
Filing date: 2022-03-08
Publication date: 2022-09-13
Also published as: DE102021202196A1

Abstract

The invention relates to a plug device, in particular for a battery pack, comprising: a plug housing; at least one electrical contact element, wherein the electrical contact element has a mating plug interface for electrical connection with a mating plug and a cable interface for electrical connection with a cable, wherein the plug housing has a contact carrier and an outer housing part which are connected to one another, wherein a casting chamber is arranged between the contact carrier and the outer housing part. It is proposed that the plug housing has an overflow chamber which is arranged in the region of the opening of the casting chamber.

Description

Plug device

Technical Field

The invention relates to a plug device, in particular for a battery pack, and to a battery pack having such a plug device.

Background

DE 102019106747 a1 discloses a plug connection element for an electric bicycle.

Disclosure of Invention

The invention relates in particular to a plug device, preferably for a battery pack, having a plug housing; at least one electrical contact element, wherein the electrical contact element has a corresponding plug interface for electrical connection with a corresponding plug and a cable interface for electrical connection with a cable or conductor element, wherein the corresponding plug interface has at least one first arm and the cable interface has at least one second arm, wherein the at least one first arm is connected to the at least one second arm via the back. It is proposed that the at least one first arm and the at least one second arm extend in the same direction from the back. A particularly compact design of the connector device can be advantageously achieved thereby.

The plug device may be configured as a plug, a plug-in, a socket, an adapter (Kupplung), or the like. The connector device is designed to be releasably connected to a corresponding connector without tools. The counter plug can be configured accordingly as a plug, a plug insert, a socket, an adapter or the like. The plug device is in particular designed for connecting lines, preferably electrical or optical lines. The counter plug likewise has electrical contact elements which correspond to the electrical contact elements of the plug arrangement. The plug arrangement is preferably provided for a battery pack, wherein a compact structure and protection of the electronics of the battery pack against the ingress of water and moisture are particularly important. The plug device has a plug axis along which the plug device can be connected with a corresponding plug in a plug direction.

The plug housing can be constructed in one piece, one piece or multiple pieces. "integral" in the context of the present application is to be understood to mean, in particular, a component which is formed from one piece, rather than from a plurality of components which are connected to one another in a material-locking and/or force-locking and/or form-locking manner. The integral component is thus composed of a single material. In the context of the present application, "one-piece" is to be understood to mean, in particular, a single component or a plurality of components that are connected to one another in a material-to-material manner. The plug housing is preferably of two-part design, wherein the housing parts are made of the same or different plastic materials. The plug housing has a receiving portion configured for receiving an electrical contact element. The electrical contact elements, in particular the arms of the electrical contact elements, can be arranged in a common or separate chamber of the plug housing. The plug housing comprises a guide element which is designed to guide the corresponding plug along the plug axis during a connection process with the plug device. The plug housing is configured as an outer housing. The plug housing preferably has a connecting element which is provided for connecting the plug device to a battery pack or other current-conducting device.

The electrical contact element is made of an electrically conductive material, in particular a metal, preferably copper or a copper alloy. The electrical contact elements are preferably constructed in one piece. The plug arrangement preferably has at least two electrical contact elements which are provided for energy supply. It is also conceivable for the plug arrangement to have further electrical contact elements which are designed or provided for transmitting data and/or information. The electrical contact elements of the plug arrangement may be configured substantially identically or differently. Preferably, the at least two electrical contact elements provided for power transmission are substantially identically constructed. The electrical contact element is preferably completely received in the plug housing of the plug device.

The cable interface of the electrical contact element is designed for connecting a cable, in particular a conductor element of a cable, to the plug device. The conductor element is configured as an electrical conductor element. The electrical conductor element can be designed, for example, as a wire. Preferably, the conductor element bears directly against the electrical contact element in the region of the cable interface. The connection of the conductor element to the electrical contact element can be effected, for example, by means of a material bond, in particular by means of a welding method or a soldering method. Alternatively or additionally, it is also conceivable to realize a force-locking and/or form-locking, for example by means of a crimping method. The second arm of the electrical contact element is assigned to the cable connection.

The corresponding plug interface of the electrical contact element is designed for connecting the plug device with a particular electrical contact element of a corresponding plug. The connection between the electrical contact elements of the plug device and the electrical contact elements of the mating plug is here effected releasably and non-destructively without tools. At least one first arm of the electrical contact element is assigned to the corresponding plug interface. The electrical contact element can have a single first arm, for example, which is designed as a contact blade (kontaktlink). It is likewise conceivable for the electrical contact element to have two first arms which are designed resiliently and form a tulip contact (Kontakttulpe). The arms can thus be configured, for example, at least as a part of a contact spring or as a flat contact.

The back, the at least one first arm and the at least one second arm are electrically connected to each other. In particular, the back, the at least one first arm and the at least one second arm are configured integrally or monolithically with one another.

"cable" is to be understood in the context of the present application to mean, in particular, a device for transmitting energy or information. The cable has an outer jacket in the form of a cable jacket in which a single-core or multi-core composite of conductor elements is arranged. The conductor elements each have an insulator. The insulation of the conductor element may be constructed integrally with the outer jacket of the cable. The plug arrangement preferably has an electrical contact element for each conductor element.

The battery pack is in particular designed as a replaceable battery pack, which is releasably connected to the consumer. The battery pack can be designed, for example, for a hand-held power tool, a garden appliance, a household appliance, a measuring appliance or an electric drive, for example in the form of an electric bicycle. The battery pack has a battery pack housing in which one or more battery cells are arranged. The battery cell may be configured, for example, as a lithium ion battery cell in the form of a cylindrical round battery cell or a pouch-shaped battery cell. In a battery pack, the battery cells are interconnected in series and/or parallel with each other. The battery pack preferably has electronics, including a battery management system.

It is furthermore proposed that the at least one first arm and the at least one second arm extend substantially parallel to one another. A compact design can advantageously be achieved thereby. Alternatively, it is also conceivable for the arms to extend toward one another.

It is furthermore proposed that the length of the second arm corresponds to at least 50%, preferably at least 75%, preferably substantially the length of the first arm. Advantageously, a compact design can be achieved thereby.

It is also proposed that the electrical contact elements are arranged completely in the plug housing. Advantageously, the electrical contact element can thus be arranged in a protected manner.

It is further proposed that the plug housing has at least one contact carrier for connecting at least one electrical contact element.

The contact carrier preferably has a receptacle for each electrical contact element, wherein the receptacle is designed for the force-fitting and/or form-fitting connection of the electrical contact element to the contact carrier. The contact carrier is designed to be partially or completely electrically insulated, so that the electrical contact elements arranged in the receptacle are electrically insulated from one another. The contact carrier is preferably made of plastic. Preferably, the contact carrier is made of plastic, in particular hard plastic. The contact carrier is in particular of one-piece or integral construction. Alternatively, it is also conceivable for the contact carrier to be constructed in multiple parts. The contact carrier has in particular a guide element of the plug housing.

Furthermore, it is proposed that the electrical contact element has at least one connection element, in particular a locking element (Verkrallungselement), for the force-fitting and/or form-fitting connection with the contact carrier. The connecting element, in particular the locking element, is in particular integrally formed with the electrical contact element and is molded on the electrical contact element. A secure fixing and exact positioning of the electrical contact element in the plug housing can advantageously be achieved thereby.

It is furthermore proposed that a separating wall which contacts the carrier is arranged between the first arm and the second arm. Advantageously, the first arm and the second arm can thereby be arranged in different regions. The connecting element of the electrical contact element can be designed, for example, for a non-positive and/or positive connection of the electrical contact element to a separating wall of the contact carrier. The separating wall advantageously extends substantially parallel to and/or in the direction of the back of the electrical contact element. The separating wall is preferably constructed integrally with the contact carrier.

Furthermore, it is proposed that the plug housing has an outer housing part, wherein the outer housing part is connected to a contact carrier, wherein the contact carrier is partially or completely received in the outer housing part. In particular, the outer housing part is of substantially pot-shaped design, wherein the contact carrier can be connected to the outer housing part along the plug axis. The outer housing part has in particular two opposite openings. The first opening is provided for connecting a contact carrier. The second opening is configured for receiving a casting needle (vergusssnadel) during casting. The connection to the contact carrier and the reception of the molded needles are thus carried out via different sides. Preferably, the outer housing part comprises a single first opening and two or more second openings.

It is furthermore proposed that the at least one second arm is arranged in a casting chamber which is formed by the contact carrier, in particular a partition wall of the contact carrier, and an outer wall of the outer housing part. A casting is arranged in particular in the casting cavity. Advantageously, the plug arrangement can be effectively sealed thereby. Furthermore, it is proposed that two second arms of two electrical contact elements are arranged in the casting chamber. The plug device may also have a plurality of casting cavities. These casting cavities can be arranged adjacent to one another or on different sides of the plug arrangement.

Furthermore, it is proposed that the casting chamber has a diameter enlargement which is provided for receiving a casting needle. Advantageously, the casting needle can be lowered into the casting chamber in order to start casting on the bottom of the casting chamber, whereby bubble formation and no casting space can be prevented. The diameter expansion has in particular a maximum width which is greater than the maximum width of the cable and the second arm in the casting cavity.

It is furthermore proposed that the diameter enlargement is arranged between the two second arms. In particular, the diameter expansion is arranged centrally between the second arms. A compact design can advantageously be achieved thereby.

The invention further relates to a plug device, in particular for a battery pack, having a plug housing; at least one electrical contact element, wherein the electrical contact element has a mating plug interface for electrical connection to a mating plug and a cable interface for electrical connection to a cable, wherein the plug housing has a contact carrier and an outer housing part which are connected to one another, wherein a casting chamber is arranged between the contact carrier and the outer housing part. It is proposed that the plug housing has an overflow chamber which is arranged in the region of the opening of the casting chamber. Advantageously, overflow of the casting can be prevented thereby. The overflow chamber is preferably configured as an overflow trough.

It is furthermore proposed that the overflow chamber is arranged in the contact carrier and/or in the outer housing part. The overflow chamber can be arranged, for example, in a side wall or at an open end of the contact carrier and/or the outer housing part.

It is also proposed that the overflow chambers extend crosswise or perpendicular to the casting direction. The casting direction may be, for example, a direction along which the casting needle can be moved towards/from the casting cavity or into the casting cavity. Alternatively or additionally, the casting direction is the direction in which the casting cavity is filled with the casting.

It is furthermore proposed that the overflow chamber extends circularly around the center axis of the connector device with a radius that is greater than the radius of the contact carrier. Advantageously, a sufficient size of the overflow chamber can thereby be achieved at the same time in a compact and simple design of the connector device.

Furthermore, it is proposed that the outer housing part and/or the contact carrier have at least one pressing rib which is designed to seal a gap between the contact carrier and the outer housing part. Advantageously, the sealing can be further improved thereby. The pressing rib is elastically and/or plastically deformable in such a way that it has a different shape in the assembled state than before the assembly of the plug device. The pressing rib is preferably constructed integrally with the contact carrier or the housing body part. The pressing rib is preferably formed integrally with the component, so that it is softer or more easily deformable. The pressing rib preferably has an elongated shape and extends in the direction of the outer housing part or the contact carrier. The gap is arranged in a region in which the housing part, in particular the outer housing part, of the plug device and the contact carrier abut against each other.

It is furthermore proposed that the plug device has at least one pressing rib for each gap in the region of the casting cavity. Advantageously, the sealing can thereby be further improved.

It is also proposed that the pressing rib has a wall thickness which is smaller than the wall thickness of the contact carrier by more than 35%, preferably more than 50%. The wall thickness may be, for example, the width of the extruded rib.

It is furthermore proposed that the electrical contact element has a corresponding plug interface and a cable interface, wherein the corresponding plug interface has at least one first arm and the cable interface has at least one second arm, wherein the at least one first arm is connected to the at least one second arm via the back.

It is furthermore proposed that the outer housing part is of double-walled design, wherein the first wall forms an outer wall and the second wall forms an inner wall, wherein the first wall and the second wall are open on different, in particular opposite, sides. The outer wall of the outer housing part forms the outer wall of the connector device, wherein the connector device is delimited by the outer wall, in particular laterally. The inner wall is formed spaced apart from the outer wall and therefore does not limit the plug device to the outside. The opposite side is preferably arranged perpendicularly or parallel to the plug axis of the connector device. The first wall and the second wall are preferably substantially parallel to each other.

It is furthermore proposed that the contact carrier has a casting cavity wall which extends substantially parallel to the first wall of the outer housing part, wherein the second wall of the outer housing part is arranged between the first wall and the casting cavity wall. Advantageously, this further improves the sealing.

It is furthermore proposed that the second arm of the electrical contact element partially or substantially completely fills the region between the second wall and the casting cavity wall. In particular, the electrical contact element partially rests against the casting cavity wall and against the second wall. If the region is only partially filled with electrical contact elements, the region is additionally filled with a casting compound in order to seal the region.

Preferably, the second wall of the housing body part rests against an open end on the partition wall of the contact carrier, in particular by pressing the rib. An effective sealing can advantageously be achieved thereby.

It is furthermore proposed that the first wall of the outer housing part has an overflow chamber at the open end.

It is furthermore proposed that the length of the second wall corresponds to at least 10%, preferably at least 30%, preferably at least 50% of the length of the first wall. Advantageously, the sealing can be further optimized thereby. It is also conceivable that the length of the second wall substantially corresponds to or exceeds the length of the first wall.

In particular, the plug device has a recess for the electrical contact element in the region of the open end of the second wall. The second arm of the electrical contact element can advantageously be guided into the casting cavity through the slot. The slot may, for example, be centrally arranged between the bottom of the casting cavity and the opening of the casting cavity. Alternatively, it is also conceivable that the slot can be arranged in the region of the bottom of the casting cavity.

The invention further relates to a battery pack or an electrical consumer, comprising a plug device as described above.

Drawings

Further advantages result from the following description of the figures. The figures, description and claims contain a number of combined features. The person skilled in the art advantageously also considers the individual features individually and summarizes them as meaningful further combinations.

The figures show:

fig. 1 is a perspective view of a battery pack with a plug arrangement;

fig. 2 is an exploded view of the plug device according to fig. 1;

fig. 3 is a perspective view of an electrical contact element of the plug device;

fig. 4 is a perspective view of the contact carrier of the plug device with an inserted electrical contact element;

FIG. 5 is a cross-section of the plug device;

fig. 6 is a rear view of the plug device;

fig. 7 shows a further perspective view of the plug device without the outer housing part.

Detailed Description

Fig. 1 shows a perspective view of a battery pack 10 with a plug device 100. The battery pack 10 is configured as a replaceable battery pack for an electric bicycle (not shown), for example. The battery pack 10 has a mechanical connecting element 12 for fastening the battery pack 10 on or in an electric bicycle. The electrical connection of the battery pack 10 to the electric bicycle is realized by a plug device 100. In particular, the electric bicycle or the charging device (not shown) has a corresponding plug (not shown) which can be plugged into the plug device 100 along the plugging axis 101 in the direction of the battery pack 10.

The battery pack 10 has a plurality of battery cells (not shown) which are arranged in a battery cell holder (not shown). The battery cell holder is, for example, arranged completely in the battery pack housing 14. Of course, it is also conceivable for the battery cell holder to form part of or the entire battery pack housing 14. The battery pack case 14 is configured as an outer case.

Also disposed in the battery pack housing 14 is electronics (not shown) including a circuit board (not shown). The electronic device includes a BMS (battery management system) configured to control and/or regulate the battery pack 10. The circuit board is connected with the storage battery monomers and is used for monitoring the voltage of each storage battery monomer.

The battery pack housing 14 has two end plates 16, which are connected to the battery pack housing 14, for example, by a screw connection. A plug device 100 is arranged in the front end plate 16. Additionally, a charge status display 18 is arranged in the front end panel 16, by means of which the charge status of the battery pack 10 or battery cells can be displayed.

The battery pack 10 and the electronics of the battery cells are connected to the connector device 100 via four conductor elements 20.

Fig. 2 shows an exploded view of the connector device 100.

The connector device 100 has a connector housing 102, which is designed, for example, in two parts. The plug housing 102 has a contact carrier 104 and an outer housing part 106. The contact carrier 104 and the outer housing part 106 are each constructed, for example, in one piece. The outer housing part 106 is substantially pot-shaped and in the connected state the contact carrier 104 is connected with the outer housing part 106 in a force-locking and form-locking manner and is received therein.

This connection is made via a first opening 108 of the outer housing part 106, the first opening 108 being of substantially circular configuration. The first opening 108 is arranged on a first side 110 of the plug device 100. On a second side 112, opposite the first side 110, the outer housing member 106 has a bottom 114. Furthermore, the outer housing component 106 has two second openings 116 arranged on the second side 112.

Furthermore, the connector device 100 has two metal clips 118, which are connected to the contact carrier 104, for example. The metal clip 118 is provided for fixing a corresponding plug (not shown) in a state of being connected to the plug device 100 or the battery pack 10.

Furthermore, the connector device 100 has, for example, four electrical contact elements 120. The electrical contact elements 120 are connected to the conductor elements 20, respectively. The electrical contact element is of one-piece design and is made of metal, for example copper.

A casting 119 is produced for sealing the connector device 100 during the assembly process through the second opening 116.

Fig. 3 shows a perspective view of one of the electrical contact elements 120 in the connected state with one of the conductor elements 20.

The electrical contact element 120 has four first arms 122. The first arm 122 is assigned to a corresponding plug interface 123 for connecting to a corresponding plug. The first arm 122 is configured for electrical connection with an electrical contact element (not shown) of a corresponding plug. Each of the two first arms 122 is designed, for example, as a spring contact for connection to a flat contact. The first arms 122 are interconnected by a back 124.

Starting from the back 124, all first arms 122 extend in the same direction. In particular, the back 124 forms a plane, wherein the first arm 122 extends substantially perpendicular to the plane.

The electrical contact element 120 also has a second arm 126. This second arm is assigned to a cable interface 121 for connecting a cable. The second arm 126 is configured for connecting the electrical contact element 120 with one of the conductor elements 20.

Proceeding from the back 124, the second arm 126 extends substantially in the same direction as the first arm 122. In particular, the second arm 126 has two

subsections

127, 128 which extend substantially parallel to the first arm 126 and are connected to one another by an intermediate section 129, wherein the intermediate section 129 extends substantially parallel to the back 124 or the plane spanned by the back 124.

The second arm 126 is designed as a flat contact 130 in the second subsection 128. In the second subsection 128, the second arm 126 is connected to the conductor element 20.

The conductor element 20 has a conductor 22, which is made of copper, for example. The conductor 22 is covered by a conductor element insulator 24, wherein the conductor 22 is exposed on the end of the conductor element 20.

The exposed conductor 22 and the flat contact 130 are connected by a crimp connection in the form of a Splice-connection (Splice-binding). This connection is made by an additional metal strip 26 which presses the conductor 22, in particular the individual wires of the conductor 22, against the flat contact 130.

Furthermore, the electrical contact element 120 has two third arms 132, which are designed as connecting elements 134, for connection to the plug housing 102, in particular to the contact carrier 104 of the plug housing 102.

Third arm 132 extends from back 124 in substantially the same direction as first arm 122 and second arm 126. The third arm 132 has a locking element 136 which projects laterally and is designed for partial penetration into the contact carrier 104 during the connection process.

The first subsection 127 of the second arm 126 also has a locking element 136, which is configured for a force-locking and form-locking connection of the electrical contact element 120 with the contact carrier 104. The locking element 136 extends substantially perpendicular to the longitudinal extension of the corresponding arm 126, 132 of the electrical contact element 120.

The length of the electrical contact element 120 substantially corresponds to the length of the longest arm 122, wherein the first arm 122 and the second arm 126 are configured substantially the same length.

Fig. 4 shows a perspective view of the contact carrier 104 in the connected state with the electrical contact element 120. The electrical contact elements 120 are arranged in different cavities.

For each electrical contact element 120, the contact carrier 104 has a corresponding plug receptacle 140. In the corresponding plug receptacle 140, the first arm 122 of the electrical contact element 120 is arranged. For example, the contact carrier 104 has a corresponding plug receptacle 140 for each electrical contact element 120. The counter plug receptacle 140 is designed, for example, as a built-in cavity which is substantially completely surrounded on the side by the walls of the contact carrier 104. In the direction of the plug axis 101, the corresponding plug receptacles 140 each have an opening 125 for an electrical contact element of a corresponding plug (see fig. 2). The other side of the corresponding plug receptacle 140 is closed by the back 124 of the electrical contact element 120.

For each electrical contact element 120, the contact carrier 104 also has a connecting element receptacle 144. The connecting element receptacle 144 is designed as a built-in cavity. The connecting element receptacle is designed for connection to the third arm 132 or the connecting element 134 of the electrical contact element 120.

Furthermore, the contact carrier 104 has an external cavity. The external cavity is embodied as a casting cavity 146. The casting cavity 146 is configured for receiving the second arm 126 of the electrical contact element 120. The contact carrier 104 has, for example, two casting cavities 146, in each of which two second limbs 126 of two electrical contact elements 120 are arranged and in part the conductor element 20 connected thereto. The casting chamber 146 is laterally only partially enclosed by the contact carrier 104, in particular a partition 148 of the contact carrier 104. The partition wall 148 is configured as a casting cavity wall 149. Furthermore, the contact carrier has a flange 150, which forms the bottom of the casting chamber 146. The casting cavity 146 and the corresponding plug receiving portion 140 are separated from each other by a partition wall 148.

Fig. 5 shows a partial cross section of the connector device 100. This cross section is illustrated through the electrical contact element 120 of fig. 3 and the associated corresponding plug receptacle 140, connecting element receptacle 144 and casting cavity 146.

The connecting element receiver 144 is laterally surrounded by a wall of the contact carrier 104. On the first side 110, the connecting element receptacle 144 is additionally closed by the wall of the contact carrier 104, and on the second side 112 by the rear 124 of the electrical contact element 120.

The corresponding plug receptacle 140 is laterally enclosed by the walls of the contact carrier 104. The outer wall is in this case formed as a partition 148 to the adjacent casting chamber 146. The partition wall 148 extends substantially parallel to the plug axis 101 of the plug device. The partition wall 148 has a length that substantially corresponds to the length of the corresponding plug receptacle 140. The counter plug receptacle 140 is hollow, with the exception of the first arm 122 of the electrical contact element 120, so that the electrical contact element of the counter plug can be received through the opening 125 (see fig. 2). The opening 125 is designed for the electrical contact element of the corresponding plug and therefore has a smaller width than the electrical contact element 120 in the corresponding plug receptacle 140.

The contact carrier 104 is connected in a force-fitting and form-fitting manner to an outer housing part 106 of the plug housing 102. This connection is effected by a connecting element 152 in the form of a latching hook which is shaped onto the flange 150 of the contact carrier 104 in the region of this flange. The latching hooks engage in the connected state into corresponding connecting elements 154 in the form of projecting tabs of the outer housing component 106.

The bottom 114 of the outer housing member 106 extends substantially parallel and adjacent to the back 124 of the electrical contact element 120.

In the region of the casting chamber 146, the outer housing part 106 is double-walled. The first wall 158 is configured as an outer wall and laterally bounds the plug arrangement 100. The first wall 158 extends parallel to the plugging axis 101 in the plugging direction. The first wall 158 has an open end 160. The open end 160 of the first wall 158 is associated with the second opening 116 of the connector device 100, through which the casting takes place. The open end 160 of the first wall 158 also includes an overflow cavity 162, which is configured as an overflow trough, for example. The overflow chamber 162 is delimited by two projections of the first wall 158 of the outer housing part 106, wherein the projections extend parallel and in the direction of the plug axis 101. The first wall 158 has a length 159 which substantially corresponds to the length of the partition walls 148 of the contact carrier 104. The length 159 of the first wall 158 is measured from the second opening 116 to the bottom of the casting cavity 146.

The second wall 164 is configured as an inner wall. The second wall 164 extends from the base 114 of the outer housing part 106 parallel to the plug axis 101 and opposite to the plug direction. The first wall 158 and the second wall 164 thus extend in opposite directions. The thickness of the second wall 164 is less than the thickness of the first wall 158. Advantageously, weight and installation space can be saved thereby. Proceeding from the second opening 116, the second wall 164 has a length 166 which, for example, corresponds to approximately 30% of the length 159 of the first wall 158. The second wall 164 thus has an open end 168 that is disposed about 30% below the second opening 116 of the casting cavity 146. It is contemplated that the open end 168 is also disposed deeper within the casting cavity 146 to further improve the seal.

The first wall 164 has, in particular, a greater distance from a central axis 170 (see fig. 6) than the second wall 158. The second wall 158 has, in particular, a greater distance from the center axis 170 of the connector device 100 than the partition wall 148 or the casting cavity wall 149 of the contact carrier 104.

The casting cavity 146 is filled up to the open end 160 or the second opening 116 with the casting 119 for sealing. In order to effectively protect the electronics of the battery pack 10, it is advantageous that moisture which may enter through the first side 110 of the plug arrangement 100 must travel as long a path as possible.

A first possible access point 172 for moisture is a gap between the contact carrier 104 on the first side 110 and the outer housing part 106, in particular in the region of the connecting

elements

152, 154. Starting from the first possible access point 172, moisture must penetrate through the casting along substantially the entire length of the casting cavity 146.

The second possible entry point 174 for moisture is the corresponding plug receptacle 140. Moisture entering through the corresponding plug receptacle 140 must slowly migrate around the second wall 164 to the second opening 116, thereby significantly improving the sealing action.

Fig. 6 shows a rear view of the connector device 100 without the casting 119. In the casting cavity 146, the second arm 126 of the electrical contact element 120 is arranged together with the connected conductor element 20.

The casting cavity 146 has an expanded diameter portion 176 configured to receive a casting needle during casting. In the region of the diameter expansion 176, the casting cavity 146 preferably has a maximum width. The width is designed in particular here perpendicular to the center axis 170 of the connector device 100. Advantageously, the diameter expansion 176 can be used to introduce a casting needle into the casting cavity 146 in order to fill the casting cavity 146 from the bottom, i.e., from the bottom to the top. The diameter enlargement 176 is arranged, for example, between two electrical contact elements 120. Alternative arrangements are also contemplated.

The overflow chamber 162 extends along a circular path around a central axis 170 of the plug device 100. The overflow chamber 162 has a length that substantially corresponds to the width of the casting cavity 146. The bottom 178 or trough bottom of the overflow chamber 162 is located below the second opening 116. The casting needles are arranged in the casting cavity 146 and in the casting 119 during casting. A portion of the casting is thus deposited on the casting needle, wherein this portion can fall off as a drop or a wire (Faden) after the end of the casting and is effectively received by the overflow chamber in such a way that the casting does not reach the outside of the plug device 100. The depth of the bottom 178 of the overflow chamber 162 corresponds in particular to at least 5%, preferably at least 10%, particularly preferably at least 20%, of the length 159 of the first wall 158.

Fig. 7 shows a partial perspective view of the contact carrier 104 with the connected electrical contact elements 120.

In order to seal the gap between the contact carrier 104 and the outer housing part 106, which is caused by the connection, the contact carrier 104 has a pressing rib 180. The pressing rib 180 is designed in particular here to seal off the casting cavity 146 in order to prevent the casting 119 from flowing out or being dislodged (Abwandern). In particular, all gaps of the casting cavity 146 are additionally sealed by the pressing ribs 180. The crush ribs 180 are integrally formed with the contact carrier 104. The wall thickness 182 or width of the pressing rib 180 is in particular less than 50% of the wall thickness of the contact carrier wall on which the pressing rib 180 is formed.

The connector device 100 has a first pressing rib 184, which is arranged in the region of the first possible entry point 172. The first crush rib 184 extends substantially circularly around the flange 150 of the contact carrier 104.

The connector device 100 has a plurality of second pressing ribs 186 which are arranged at the ends of the separating walls 148 of the contact carrier 104. Thus, the second pressing rib 186 is arranged in the region of the second possible entry point 174.

Furthermore, the connector device 100 has an additional third extrusion rib 188, which extends substantially perpendicularly to the first and second extrusion ribs 184, 186, in particular along the length of the casting chamber 146.

Claims

1. A connector device, in particular for a battery pack (10), having:

a plug housing (102);

at least one electrical contact element (120), wherein the electrical contact element (120) has a mating plug interface (123) for electrical connection with a mating plug and a cable interface (121) for electrical connection with a cable (20) or a conductor element, wherein the plug housing (102) has a contact carrier (104) and an outer housing part (106) which are connected to one another, wherein a casting chamber (146) is arranged between the contact carrier (104) and the outer housing part (106),

it is characterized in that the preparation method is characterized in that,

the plug housing (102) has an overflow chamber (162) which is arranged in the region of the opening (116) of the casting chamber (146).

2. Plug device according to claim 1, characterized in that the overflow chamber (162) is arranged in the contact carrier (104) and/or in the outer housing part (106).

3. Plug device according to one of the preceding claims, characterized in that the overflow chamber (162) extends crosswise or perpendicular to the casting direction.

4. Plug device according to one of the preceding claims, characterized in that the overflow chamber (162) extends circularly around a central axis (170) of the plug device (100) with a radius which is larger than the radius of the contact carrier (104).

5. Plug arrangement according to one of the preceding claims, characterized in that the outer housing part (106) and/or the contact carrier (104) have at least one pressing rib (180) which is configured for sealing a gap between the contact carrier (104) and the outer housing part (106).

6. Plug device according to claim 5, characterized in that the plug device (100) has at least one extruded rib (180) for each gap in the region of the casting cavity (146).

7. Plug arrangement according to claim 5 or 6, characterized in that the pressing rib (180) is constructed integrally with the contact carrier (104) or with the outer housing part (106).

8. Plug arrangement according to one of the preceding claims, characterized in that the pressing rib (180) has a wall thickness (182) which is smaller than the wall thickness of the contact carrier (104) by more than 35%, preferably by more than 50%.

9. Plug device according to one of the preceding claims, characterized in that the corresponding plug interface (123) has at least one first arm (122) and the cable interface (121) has at least one second arm (126), wherein the at least one first arm (122) and the at least one second arm (126) are connected by a back (124).

10. Plug device according to one of the preceding claims, wherein the outer housing part (106) is configured as double-walled, wherein a first wall (158) is configured as an outer wall and a second wall (164) is configured as an inner wall, wherein the first wall (158) and the second wall (164) are configured open on different, in particular opposite sides.

11. Plug device according to claim 10, characterized in that the contact carrier (104) has a casting cavity wall (149) which extends substantially parallel to the first wall (158) of the outer housing part (106), wherein the second wall (164) of the outer housing part (106) is arranged between the first wall (158) and the casting cavity wall (149).

12. Plug device according to claim 11, characterized in that the second arm (126) of the electrical contact element (120) partially or completely fills the area between the second wall (164) and the casting cavity wall (149).

13. A plug device according to any one of claims 10 to 12, in which the first wall (158) of the outer housing part (106) has an overflow chamber (162) on an open end (160).

14. Plug arrangement according to one of claims 10 to 13, characterized in that the length (166) of the second wall (164) corresponds to at least 10%, at least 40%, preferably at least 70% of the length (159) of the first wall (158).

15. Battery pack or consumer device comprising a plug device (100) according to any one of the preceding claims.