DE102022211544A1 - Connector layout and connectors - Google Patents

Abstract

The invention relates to a plug connector arrangement (100) with a plug connector (1) and a mating plug connector (2), wherein the plug connector (1) has a contact chamber (14) with an outer wall (15) and a lamella cage (3) with a base element (4), a plurality of contact lamellas (5) and a coupling section (42), wherein the contact lamellas (5) have a contacting section (41), wherein the lamella cage (3) is arranged in the contact chamber (14), wherein the contacting sections (41) are curved in the direction of the outer wall (15) with respect to a rear section (6) and a front section (7) of the contact lamellas (5), wherein the mating plug connector (2) has a contact element (9) with a bottom side (35), wherein the mating plug connector (2) can be displaced along an insertion direction (E) at least up to a first position (P1) with a force of less than 5N and in a second position (P2) of the mating connector (2), the contact element (9) mechanically contacts the coupling section (42) of the lamella cage (3) such that the contacting sections (41) of the contact lamellas (5) are displaced along a radial direction (R) towards the outer wall (15) and thereby electrically contact a contact section (13) of the outer wall (15).

Description

Field of the invention

The invention relates to a connector arrangement and a connector.

State of the art

Connector arrangements usually have a connector and a mating connector that can be plugged together. Connectors for high-current applications (e.g. for electrical currents of more than 10A, preferably more than 50A or even more than 100A), e.g. for electric vehicles or for automotive applications, often have contact elements with spring lamellas, e.g. toroidal or sleeve-shaped lamella cages, which are connected to a (e.g. shielded) cable, e.g. by means of a mechanical crimp connection or by means of ultrasonic welding. In other cases, the lamella cages can also be connected directly to a carrier element, e.g. a circuit board, e.g. soldered or by means of a press-fit contact. Such connectors are designed to be connected to a mating connector, which can have a contacting part, e.g. in the form of a contact pin or a contact blade or the like. The connector can, for example, be plugged together with the mating connector along a plug-in direction or a plug-in direction. In the final state, a contact element of the mating connector (also referred to as a mating contact element) makes electrical contact with the contact element of the connector. In the final plugged-together state, the spring blades of the contact element of the connector should have a normal force (or contact normal force) that ensures that an electrical connection to the mating contact element is guaranteed even under mechanical and/or thermal load and across all manufacturing tolerances.

However, this normal force is usually limited because the insertion forces when connecting the connector to the mating connector should not exceed a defined level. In order to reduce the high insertion forces for an operator, lever constructions or slide constructions can be provided, for example, so that the operating force when plugging together is reduced. However, such lever or slide constructions are often complex and expensive and require a large amount of movement to operate and do not prevent damage to the surfaces rubbing against each other when the contact element of the mating connector slides along the contact blades. It is possible to reduce the insertion forces by applying a friction-reducing coating to at least one contact partner (contact element and/or mating contact element) and also to reduce damage to the surfaces during the plugging process. However, this increases the costs and complexity of the manufacturing process of the corresponding contact partner and does not reliably prevent damage to the surfaces of the contact partners. In addition, this can sometimes increase the contact resistance in the area of the contact point.

In other applications, the contact partners (contact element and counter-contact element) can be designed as busbars, for example. These can be screwed together, for example, to ensure permanent contact. When screwed together, for example with M4 screws, a so-called contact force or normal force in the range of 2000N to 2500N can be achieved. If M5 or M6 screws are used, even higher normal forces can be achieved. However, screwing the contact partners in this way requires additional installation space for arranging the screws and the means to tighten or loosen the screws in the event of maintenance. In addition, several additional steps are necessary before and/or after the contact partners are put together, which make the assembly process complex: the contact partners must be precisely aligned with one another in order to be able to tighten the screw, the screw must be placed, an aid for tightening the screw must be placed, the screw must be tightened, the aid must be removed.

From the EN 10 2018 202 960 A1 is a connector for automotive applications and/or high-current applications in which the contact element is designed as a lamella cage. In order to reduce the high insertion forces (between the contact element and the mating contact element) that occur for an operator when plugging together, a lever element is provided that is actuated during the plugging process when plugging together the connector and the mating connector.

From the EN 10 2017 213 093 A1 A plug contact for high-current applications is known, whereby the contact element is designed as a lamella cage and in which a high insertion force (between contact element and mating contact element) must be overcome during the insertion of a mating contact element into the contact element.

From the EN 10 2019 131 791 A1 A contact element of a connector is known, whereby the contact element is directly connected to a circuit board and wherein the contact element can be contacted by inserting a pin-like contact element of a mating connector.

From the DE 20 2008 005 394 U1 A high-current printed circuit board connector with a lamella cage is known, wherein the connector can be pressed into a printed circuit board by means of a plug-in base and can thus be electrically contacted.

From the WO 2007 / 107 208 A1 A plug connection of the Radsok type (Radsok connector) with a socket of the Radsok type (Radsok socket) and a plug that can be plugged into the socket is known, which form a plug connector arrangement when plugged together, wherein locking means are formed on the Radsok socket and the plug, which enable a defined fixing of the Radsok socket and plug.

Disclosure of the invention

The invention is based on the knowledge that if there is a low normal force (at the contact point(s) between the contact element and the mating contact element) in the event of high temperature fluctuations and/or strong vibration or shaking loads, there is a risk that undesirable relative movements between the contact partners (contact element and mating contact element) and/or contact interruptions can occur. The invention is also based on the knowledge that the largest possible contact area between the contact partners is useful for a long service life of the contact and/or for low heating of the contact point when transmitting high currents. The invention is also based on the knowledge that high insertion forces over a large portion of the path when plugging together the connector and mating connector complicate the plugging process. Furthermore, the invention is based on the knowledge that the application of the normal force between the contact element and the mating contact element, particularly when these are socket contacts (female contact element) and contact pin or contact blade (male mating contact element), already during the plugging process - i.e. on the way or a large part of the way, e.g. more than 30% of the way, e.g. from a pre-plug position via an intermediate plug position (first position) to a final plug position (second position) - not only complicates and makes the plugging process more difficult, particularly when several plug connectors are plugged together with several mating plug connectors at the same time, but that the surfaces of the respective contact partners can also be affected. For example, if the normal force is applied during the plugging process, a contact blade can leave a grinding mark or a scratch on a contact part to be contacted. This can undesirably damage or destroy a surface coating and can be detrimental to repeated plugging and unplugging, as such scratches or grooves can cause the contact partner to get caught during the plugging or unplugging process. A high insertion force (between the contact partners) can even reduce the number of contact partners in a connector in an undesirable way, as with a high number of contact partners, the insertion forces can become so high, even when lever or slide constructions are used, that the operating force is no longer reasonable for an operator. Furthermore, the invention is based on the knowledge that the coating of the contact partners can reduce the current-carrying capacity and increase costs. Finally, the invention is based on the knowledge that lamella cages that are firmly connected to or in or on the connector, in particular by means of a material bond or pressed into a chamber, can lead to a defective lamella cage leading to a total economic loss of the connector, as the lamella cage cannot be replaced with reasonable effort. This affects sustainability.

There may therefore be a need to provide a connector arrangement that enables the connection or plugging together of a connector with a mating connector (which can also be designed as a male connector or the like, for example) with the lowest possible plugging force, which at the same time has a high normal force between the contact partners in the electrically contacted state, which has a high current-carrying capacity, which provides the largest possible contact area between the contact partners, which enables permanent, safe, reliable and uninterrupted electrical contact between the connector and the mating connector even under alternating thermal loads and/or mechanical loads such as vibration loads or shaking loads, which requires only a small installation space or assembly space for the contacting process, which enables safe operation (no risk of touching live parts), in which at least the contact partners (contact element and mating contact element) can be manufactured inexpensively and easily, in which the establishment of the contact with the desired normal force is possible in a simple manner with as few steps as possible and even in complicated installation space situations and which can be repaired in a simple manner so that a sustainable product is provided.

Similarly, there may be a need to provide a connector having the characteristics described above.

Advantages of the invention

This need can be met by the subject matter of the present invention according to the independent claims. Advantageous embodiments of the present invention are described in the dependent claims.

According to a first aspect of the invention, a connector arrangement is proposed, in particular for high-current applications and/or high-voltage applications, in particular for automotive applications, in particular for electric vehicles (which may also include, for example, fully or partially electrically powered aircraft, ships, boats, e-bikes, motorcycles).

The connector arrangement has a connector and a mating connector for mating with the connector. The connector has a lamella cage with a base element and with a plurality of contact lamellas. The contact lamellas are connected to the base element in a rear section; they protrude from the base element in the direction of the mating connector. The contact lamellas have a front section which faces the mating connector and which has a cantilevered end or through which the contact lamellas are connected to a head element of the lamella cage (in this alternative, the contact lamellas are connected to the head element by means of the front section). The contact lamellas have a contacting section which is arranged between the rear section and the front section. The lamella cage has a coupling section. The connector has a contact chamber with an outer wall. The lamella cage is arranged in the contact chamber. The contact sections are curved in the direction of the outer wall with respect to the rear section and the front section, in particular e.g. in the force-free state. The mating connector has a contact element with an underside facing the lamella cage. The contact element and/or the mating connector can be displaced between a first position and a second position, in particular along a plug-in direction, in particular when plugged together with the connector. At least up to the first position, the contact element and/or the mating connector can be displaced along the plug-in direction with a force of less than 5N, in particular without force. In the second position, the contact element mechanically contacts the coupling section of the lamella cage in such a way that the contact sections of the contact lamellas are displaced towards the outer wall, in particular along a radial direction, and the contact sections thereby electrically contact a contact section of the outer wall.

This advantageously means that the lamella cage can be mounted particularly easily and reliably in or on the connector and can also be dismantled again. It can, for example, be plugged or pushed into the contact chamber. This automatically arranges it in the correct position in the connector. Another advantage is that a particularly large electrical transition area can be formed from the lamella cage to the connector by means of the defined contacts of the majority of the contact lamellas on the contact section of the outer wall, which reduces the contact resistance. This is also possible if the lamella cage is not pressed particularly tightly against the contact chamber in the first position or directly after assembly, or even if the lamella cage is arranged loosely in the contact chamber. Furthermore, an additional electrical conduction path can be formed at least in the second position, for example, by a base of the contact chamber being electrically contacted with the base element when the force of the contact element presses the lamella cage against the base of the contact chamber. In this way, a complex press-in assembly, e.g. in a circuit board, or soldering or welding of the lamella cage, e.g. to a carrier substrate or an electrical component, can be dispensed with, or even a complex press-in assembly or the like in a contact chamber.

The electrical contact between the lamella cage and the contact element (and thus between the connector and the mating connector) can be achieved, for example, by mechanically contacting the coupling element and the contact element. This can be achieved, for example, by applying an axial force to the coupling area, e.g. through the underside of the contact element. In this way, a high contact normal force can advantageously be achieved between the contact element and the coupling area or coupling section, without the contact element and the coupling area or coupling section having to cover a longer axial friction distance relative to one another, which could damage the surfaces of the contact partners.

It can be provided, for example, that the outer wall of the contact chamber in the force-free state of the lamella cage rests loosely on the contacting sections of the contact lamellas or is preferably spaced from the base element by a (radial) gap, e.g. by a gap of at most 500um, preferably at most 200um and particularly preferably at most 100um. In this way, the lamella cage is still easy to insert into the contact chamber, ideally without force. At the same time, however, it is positioned very precisely with respect to the radial direction, which ensures a simple and reliable joining process with the mating connector and also leads to radial contact between the contact sections and the contact section even with a small axial compression path, in particular with a high contact normal force. This results in a high possible path-force ratio.

Another advantageous effect is that the joining or plugging together of the plug connector and the mating connector can be carried out largely force-free or with a very low insertion force and the contact element of the mating connector is only actually subjected to the contact normal force at the end of the plugging process. In contrast to conventional lamella cages, in which the plugging process of a male mating contact element of the mating connector already in the area of the contact lamellas has to widen them radially outwards (so-called "beak peak" in the insertion force) and the friction force between the contact lamellas and the contact element also has to be overcome on the further path, according to the invention an increased force only has to be applied at the end of the plugging process or the joining process, which is necessary so that the contact lamellas are displaced radially outwards or radially towards the outer wall (in particular by axial compression) and can thus apply the contact normal force to the contact element. This advantageously simplifies the assembly process, also advantageously enables larger manufacturing tolerances, since tilting due to the insertion forces is prevented, and also advantageously enables the arrangement of the connector and mating connector to be corrected during the assembly process (at least up to the first position). Another advantage is that the joining process and/or plugging process in a production line can also be distributed across different, spatially separate machines or workstations: in a first step, the connector and mating connector are, for example, simply plugged together or joined until the first position is reached. This is done essentially without force or with a very low insertion force. In this first position, the contact element of the mating connector is advantageously already in loose mechanical contact with the coupling section or is only slightly spaced from it (along the insertion direction), e.g. at most 200um or at most 100um). In a second step (which can also be carried out at another workstation or by other machines or fitters), the normal contact force can then be applied and thus the desired electrical (and also mechanical) connection can be formed. In this way, pre-assembly is possible. It may also be possible, for example, for the pre-assembly process (reaching the first position) to be secured, e.g. mechanically, e.g. by a type of primary locking, so that the pre-assembled connector arrangement can be transported to another location without any problems and without being lost.

In addition, this advantageously prevents - as in the prior art - the surfaces of a male counter-contact element and contact lamellae from being damaged or destroyed during the joining process along a longer path (e.g. from the beginning of the overlap of the contact lamella contact point and the contact part of the contact element to a contact section of the contact part). This is because the axial force exerted causes the lamellae to be displaced primarily radially when the lamella cage is compressed and not, or only very slightly, in the axial direction. There is therefore hardly any frictional movement between two surfaces along the axial direction. This also enables the connector and mating connector to be plugged together and unplugged several times (e.g. for repairs, maintenance, etc.), which advantageously improves the sustainability of the connector arrangement and the associated components.

Furthermore, the number of contact blades can be increased in comparison to conventional connector arrangements (with a male counter-contact element which is inserted into the interior of a blade cage or a socket contact and has to push the contact blades there apart during the insertion path) and/or the normal force applied to the contact blades in the final plug-in position can be increased. Alternatively or additionally, a material can be used for the contact blades which has a higher spring constant or a higher modulus of elasticity. This can advantageously achieve an improved current-carrying capacity over the lifetime, the thermal load on the contact partners in the contact area can advantageously be reduced (lower contact resistance) and the connector arrangement can therefore have increased robustness, e.g. against alternating thermal loads, vibrations and/or manufacturing tolerances. An increased axial force only has to be applied at the end of the plugging process - on the (particularly short) path from the first position to the second position - in order to apply a radially acting contact normal force (between the contact blades and the outer wall). This axial force also influences the contact normal force between lamella steering cage and contact element. Because of the small axial path with increased force expenditure, an actuating element can be arranged on the plug connector and/or on the mating connector, for example, which has a particularly high force transmission despite a possibly limited operating path (e.g. more than 10:1 or more than 50:1, or more than 100:1). In cases with small installation space and little room for the movement of such an actuating element, the proposed invention can ensure that a significant force transmission is possible with simple means. Such an operating element or actuating element - which can be provided optionally but is not absolutely necessary and therefore not essential - can be designed as a lever or a slide, for example. Such an actuating element can be arranged, for example, on a plug connector housing or on a mating connector housing. It can, for example, have a link structure which interacts with a complementary pin or bolt on the mating element (if the actuating element is arranged, for example, on the connector or on the connector housing, then the bolt or pin can be arranged on the mating connector or mating connector housing).

Compared to a contact that acts purely in the axial direction, in which the lamella cage is only clamped axially between a base of the contact chamber and the contact element, the number of contact points between the lamella cage and the contact chamber is advantageously increased. This advantageously increases the current-carrying capacity, reduces the electrical contact resistance, increases the redundancy of the contact points, reduces the thermal load on the contact point and also further improves the robustness against manufacturing tolerances and against vibrations and/or shaking loads. This is because the contacts between the base element and the base of the contact chamber are formed along the axial direction and are thus orthogonal to the contact points between the contact lamellas and the outer wall, which preferably act or are formed in the radial direction.

The insertion direction can be defined, for example, as the direction along which the mating connector is plugged into the connector. It can preferably be defined, for example, as the direction along which the contact element is displaced relative to the lamella cage in order to make contact. The insertion direction can also be referred to, for example, as the axial direction.

The radial direction runs perpendicular to the insertion direction. A circumferential direction runs around the insertion direction.

The contact lamellae can, for example, be curved with their contact sections in the radial direction towards the outer wall or in the direction of the outer wall.

In the second position, the contact sections of the contact lamellas can, in conjunction with the contact section of the outer wall, clamp the lamella cage, e.g. between the outer wall. This has the advantageous effect that a lamella cage that is initially loosely inserted into the contact chamber, for example, has a secure and permanent contact with the contact chamber in the final contacted state (second position). If the contact element is moved back to the first position or even further back, the lamella cage can sit or be arranged loosely in the contact chamber again, e.g. through an elastically reversible design of the contact lamellas, and can thus be easily replaced, e.g. for repair or maintenance.

The coupling section can be contacted, for example, by an underside of the contact element that faces the coupling section. This underside can be essentially planar, level or flat. The contacting or the mechanical force effect of the contact element on the coupling section can, for example, essentially take place along the axial direction or the insertion direction.

The coupling section can be formed, for example, by the front section or by the head element.

The protrusion of the contact section or sections can be understood to mean that, viewed in the radial direction, in the force-free state, the contact section is less spaced from the outer wall (or is closer to the outer wall) than the front section and/or the rear section. This can advantageously have the effect that in a simple manner - without further material influence such as targeted weakening or strengthening of the material or thermal, chemical or other treatments - an axial compression of the lamella cage leads to a displacement of the contact lamellas in the contact area even closer to the outer wall and ultimately to contact. In other words: an axial force then leads to an even further protrusion towards the outer wall. The contact lamellas therefore have a well-defined preferred direction for displacement. when subjected to axial force or axial compression.

The contact element can, for example, cover the coupling section in the radial direction or protrude beyond the coupling section, e.g. by at least 500 µm, particularly preferably by at least 1 mm. It can, for example, completely cover the coupling section. This advantageously results in particularly reliable mechanical contact when moving from the first to the second position and in the second position. This also advantageously means that positioning tolerances in the radial direction are not problematic.

For example, in contrast to conventional contact elements, which are inserted into the interior of the lamella cage as male contact elements, the contact element may not have a contact part protruding from a head section of the contact element. Rather, the underside may be designed without such a contact part. The contact element may be essentially flat on the underside in a side view, for example. In other embodiments, however, it may also have a centering part which protrudes from the underside like a male contact part. Such a centering part may be used, for example, to guide the contact element into the correct (radial) position relative to the lamella cage when plugging together. It may, for example, be threaded into the interior of the lamella cage and thus center the contact element in the radial direction. Furthermore, this can simplify the guidance of the contact element (compared to a contact element with a flat or level underside), so that tilting during assembly, in particular when moving from the first position to the second position, is prevented. Such a centering part can, for example, be formed in one piece with the head section of the contact element. However, it can also be made from a different material, e.g. from an insulating material, and/or be subsequently coupled or connected to the head section to form a unit that is only then present.

Such a centering part can, for example, protrude at least 2 mm from the contact element or a head section of the contact element, preferably at least 5 mm and particularly preferably at least 10 mm.

The lamella cage can, for example, be designed so that the contact element with such a centering part can be inserted into an interior of the lamella cage.

The base element and/or an optionally present head element of the lamella cage can also be referred to as a collar, for example, or can be designed as a collar to which the contact lamellas are attached. The base element and contact lamellas or the head element and contact lamellas can be made in one piece, e.g. from a single piece of sheet metal. They can be designed as a stamped and bent part, for example. The contact lamellas can be designed to contact the contact section, in particular to contact it electrically. If a head element is provided, the head element can be designed or serve or act as a coupling section, for example. It can then protrude the furthest in the direction of the contact element, for example, or form a kind of front side of the lamella cage with respect to the contact element. In this configuration, the head element can even out the force distribution on the individual contact lamellas even if the force is applied unevenly by the contact element (e.g. if it is tilted). This also applies in the case of an established contact, where, for example, vibrations lead to a changing force distribution along the head section. This results in a particularly safe and uniform contact of the contact section of the outer wall with a well-defined contact normal force.

The contact blades can, for example, have a self-supporting or free end in the front section or can be self-supporting in the front section. It can, for example, be provided that the contact blades are not connected to one another in the front section. Such a free end can, for example, point directly in the direction of the mating connector and thus represent a kind of front side of the contact blade in the direction of the contact element. However, there can also be embodiments in which the contact blades are bent at or with their free end and, for example, point in a radial direction (radially inward or radially outward) or even point in the direction of the base element. In such a case, part of the front section forms the front side that protrudes furthest from the base element in the direction of the contact element. This front side or the front section or the free ends can represent the coupling section in this configuration. This can advantageously result in a particularly high number of contact points between the blade cage and the contact element.

The shift between the first position and the second position can, for example, take place along the insertion direction. The first position can, for example, be an intermediate insertion position in which a large part (e.g. more than 70%, preferably more than 90%) of the insertion path between the connector and the mating connector has already been covered. The second position can, for example, be a final insertion position.

In the first position, for example, a gap can be formed between the contact sections and the outer wall (with simultaneous overlap of the contact sections and the outer wall). This gap can, for example, allow radial play between the contact chamber or outer wall and the contact lamellae or lamella cage. In this way, the lamella cage can be easily installed or removed.

In the second position, the contact lamellas, in conjunction with the outer wall, can clamp the lamella cage, e.g. between the outer wall. The clamping can be formed along the radial direction, for example. The term "clamping" here means that the lamella cage - assuming that the contact element remains unchanged on the coupling section in the second position - is held or clamped securely in the contact chamber by the contact lamellas. The lamella cage is thus clamped or firmly clamped between the outer wall or inside the contact chamber, viewed along the radial direction. In other words: in the second position, the lamella cage has an excess in relation to the contact chamber with respect to the space delimited by the outer wall (with only two contact lamellas that are almost opposite each other, the excess could be formed, for example, with respect to the distance between the contact lamellas).

For example, it can be provided that the contact lamellas and the outer wall enclose a contact space between them.

In other words: The contact space can be formed radially outside the contact lamellas. It can be part of an external space of the lamella cage, for example.

For example, the contact chamber can have an oversize (particularly along the radial direction) in relation to the laminar cage when it is not fully assembled (i.e. during the insertion or joining process up to the first position). When it is fully assembled, particularly in the second position, the laminar cage can have an oversize (particularly along the radial direction) in relation to the contact chamber.

The term "force-free" is to be understood in such a way that the joining or mating of the connector and mating connector, at least up to the first position, requires only an insignificant amount of force or an insignificant insertion force, and in particular no beak peak for pushing contact blades apart or a friction force between the contact partners has to be overcome. In particular for power contacts for high-current applications or high-voltage applications, a joining force or mating force of less than 10N, preferably less than 5N and particularly preferably less than 3N can be considered "force-free".

The contact blades can be designed to be elastically reversible, for example. This means that when the contact element returns from the second position to the first position, the contact blades return to their original position (i.e. they move radially away from the outer wall). This also makes it possible to unplug or separate the contact without requiring a great deal of unplugging force and/or without damaging the surfaces of the contact partners (outer wall to contact blades, but also, for example, coupling section to contact element). In addition, a renewed plugging or joining process is then possible (almost) force-free, at least up to the first position.

It can be provided - particularly in the case of contact blades that are arranged opposite one another - for example, that the contact element mechanically contacts the coupling section in such a way that the contact blades, in particular their contacting section, are displaced radially outwards on the path of the mating connector or in particular the contact element from the first position to the second position and the contacting sections thereby electrically contact the contact section of the outer wall. In the second position, the contact blades or their contacting sections are then displaced radially outwards or radially towards the outer wall and contact the contact section.

On the way from the first position to the second position and in the second position, the contact element can, for example, be in axial contact with the coupling section of the lamella cage and thereby exert an axial force on the lamella cage and in particular on the contact lamellas, which leads to the at least partial displacement of the contact lamellas in the radial direction towards the outer wall. In the second position, the contact element can be pressed onto the coupling section, in particular along the axial direction.

The contact element can be designed as a single piece. For example, in the case where a contact element is provided with a head section and a centering element or centering part protruding from it in the direction of the laminar cage, the centering part and the head section cannot be designed to be detachable from one another without causing damage. It can be provided, for example, that the head section and the centering part are rigidly connected to one another, in particular not displaceable relative to one another. It can alternatively be provided that the head section is displaceable relative to the centering part, e.g. along the axis of the centering part. For example, the centering part can be movable through an opening in the head section. The centering part and head section can be made of an electrically conductive material, e.g. the same material. In an alternative embodiment, the head section and/or an underside of the head section can be made of a different material than the centering part, e.g. the centering part can be made of an insulating material, wherein the centering part is designed or configured or serves only for the radial positioning of the contact element relative to the laminar cage.

The contact element or the head section or the underside can, for example, be designed to be electrically conductive, in particular in those areas that are mechanically in contact with the coupling section in the second position.

An optional centering part can, for example, have a diameter in the range between 2mm and 30mm, preferably between 4mm and 20mm.

A single contact lamella can, for example, have a thickness in the range of 200um (200 micrometers) to 3mm, preferably between 400um and 2mm. A lamella width or width of a lamella can, for example, be greater than the thickness of the contact lamella.

For example, it can be provided that the diameter of the outer wall of the contact chamber is at least 20 µm larger than a diameter of the lamella cage, preferably at least 50 µm.

The term “include” is used synonymously with the term “have”, unless otherwise specified.

In a further development, it is provided that in the second position the contact lamellas contact the contact section with a contact normal force in the radial direction of at least 1N, preferably at least 5N. For example, the contact normal force of the contact lamellas, in particular each contact lamella or the majority of contact lamellas, is in a range between 5N and 50N or even between 5N and 200N. This advantageously results in particularly safe and reliable contact, which has a low contact resistance over its service life even in the event of vibrations, thermal cycling or other operating conditions. This advantageously allows heating at the transition between the contact partners to be kept to a minimum even with high currents of, for example, more than 50A or even more than 100A. This also advantageously allows the installation space, weight and material usage in the contact zone to be reduced, in particular at the lamella cage, since reliable contact using a high contact normal force enables a small number of contact points. This also advantageously increases the service life of the connector arrangement.

In a further development, it is provided that the base element and/or the head element of the lamella cage is designed to be closed all the way around. This advantageously ensures that the lamella cage is designed to be particularly stable and that the contact lamellas cannot spread the base element apart in the second position. This advantageously ensures that the contact normal force is applied particularly reliably and permanently. A closed head element advantageously provides stabilization in the same way. It also prevents the head element from spreading open when mechanically contacted by the contact element, thus preventing contact with the contact part from being lost in sections or completely.

It can be provided, for example, that the base element and/or the head element or the collar (the further collar) or the collar area (or the further collar area) of the lamella cage is designed to be annularly closed.

The base area and/or the head element can, for example, have a circular or elliptical cross-section in the force-free state (i.e. before the mating connector is mounted). In principle, however, a polygonal, e.g. triangular, square, pentagonal, hexagonal, heptagonal or octagonal cross-section of the base element and/or the head element is also conceivable. More than eight corners are also conceivable.

The circumferentially closed shape can be achieved, for example, by rolling up an originally flat stamped and bent part, e.g. made of a metal sheet. In order to keep the base area and/or the head element closed, a material connection (e.g. by a welding process or an adhesive process or a soldering process) can be provided. However, a form-fitting connection can also be provided, e.g. at one end of the base area and/or the head element at least one type of eyelet or a type of recess with a neck area with a flat or narrow neck can be formed and at the other end of the base area and/or of the head element at least one type of tenon with a shape complementary to the eyelet or the recess (tongue and groove principle). After the stamped and bent part has been rolled up, the at least one tenon can then be inserted into the complementary at least one associated eyelet or recess so that the base element and/or the head element cannot unroll again. A positive connection advantageously enables a particularly simple and cost-effective assembly and temperature-stable connection.

In a further development, it is provided that the first position and the second position are at most 5 mm apart along the insertion direction, preferably at most 2 mm and particularly preferably at most 1 mm. This advantageously ensures that the contact partners (contact blades, in particular their contact sections and outer wall, in particular their contact section; possibly also coupling section and contact element or its underside) can only rub against each other along a very short, in particular axial, path and damage to the surfaces is thereby prevented or limited to a very short path range. Furthermore, this advantageously makes it possible to provide a connector arrangement that requires only an extremely small installation space along the insertion direction. Finally, a particularly high normal force can advantageously be applied in this way, for example if an actuating element is provided to reduce the operating force. If, for example, the distance between the first position and the second position is 1mm and the distance of an optional actuating element, such as a slide element or a pivoting lever element, is 100mm, then a force ratio of 100:1 can be achieved. The entire distance of the actuating element and thus the entire force ratio can thus be used to apply the contact normal force. It is not necessary to waste part of the actuating path for part of the joining path. Another advantage is that the force ratio can be very uniform along the actuating path, e.g. by means of an essentially linear link path with a uniform gradient in the actuating element. This is because an optionally available actuating element only needs to be used for the distance from the first position to the second position and not for the entire joining path. Alternatively, the actuating path can be reduced with the same force ratio, which can save installation space or free space for actuating the actuating element.

In a further development, it is provided that in the first position the radial play between the contacting section and the outer wall is in a range between 5um (5 micrometers) and 200um (200 micrometers) or in a range between 20um and 100um. This has the advantageous effect that a high contact normal force can be formed even with a short distance between the first position and the second position. A high force transmission can also be achieved advantageously, since only a very small radial path has to be covered for contacting or only a very small gap has to be closed. If, for example, an axial path of 1mm is available between the first and second positions and the gap or radial play is 100um all around, a force transmission of 10:1 can already be achieved. At the same time, such a small radial play already advantageously enables the insertion or joining process to be carried out almost force-free, at least up to the first position. Such a small clearance also enables a particularly compact design of the laminar cage and/or the connector in the radial direction.

In a further development, a groove with an inner groove wall, a groove base and an outer groove wall is introduced into the underside of the contact element to accommodate the coupling section.

This advantageously ensures that the coupling section or the head element or the contact blades (in particular with their front section or the part of the contact blade that protrudes furthest from the base element in the direction of the contact element (with their front side)) can be received or arranged in the groove, and are arranged or received in the groove in particular in the second position. This capturing of the coupling element or the head element or the contact blades can, for example, already take place in the first position of the contact element. This in turn advantageously ensures that when the contact element is (further) moved from the first position to the second position, the coupling section or the head element or the front sections of the contact blades are always in a defined position and the pressing process of the contact blades in the radial direction against the outer wall takes place in a particularly defined and reliable manner. At the same time, tilting or jamming of the contact element or its head part is prevented when moving from the first position to the second position, which could be caused without the groove by individual contact lamellas, the front section of which could be radially misplaced due to manufacturing tolerances, etc. The groove thus catches the front sections and then enables the contact element or its head part to be jammed when moving to the second position. tion the correct establishment of the plug connection in the contact section.

Furthermore, such a groove can advantageously increase the contact area between the coupling section and the contact element and thus between the lamella cage and the contact element, in particular compared to an embodiment in which contact is only made on a flat underside. This is because by moving the contact element into the second position, the part of the coupling section or the head element or the contact lamellas caught in the groove can ultimately only expand in the radial direction in the groove, since the axial space available to the contact lamella is shortened. This expansion in the groove leads to a greater filling of the groove with parts or with material of the contact lamella and thus to a larger contact area (the groove has an inner groove wall, a groove base and an outer groove wall). Furthermore, by filling the groove more with material from the contact lamella, the force of the contact lamella in the groove on the groove walls and the groove base is increased, which increases the normal contact force of the coupling section or the head element or the contact lamellas to the boundary surfaces of the groove (groove walls and groove base). This advantageously creates additional contact paths in the groove, which increases the redundancy of the contact points, reduces the contact resistance and advantageously increases the reliability and service life of the connector arrangement and in particular of the contact point. Alternatively or additionally, the groove can clamp the coupling section or the head element or the contact lamellas in the radial direction (between the inner wall of the groove and the outer wall of the groove) and thus create lateral contact surfaces. This can be achieved in particular if the groove is narrow enough at least in sections that, for example, the coupling section or head element or the contact lamellas have an excess with regard to a distance between the inner wall of the groove and the outer wall of the groove.

The groove can, for example, be designed to be circumferential. It can, for example, be designed to be closed, in particular to be closed all the way around. It can, for example, have the same cross-section everywhere.

If a centering part is present, the groove can be arranged between the centering part and an edge of the underside. It can, for example, run around the centering part in the direction of rotation.

This advantageously increases the number of contact points between the laminar cage and the contact element, reduces the contact resistance and improves robustness against vibrations, thermal loads and manufacturing tolerances.

It can be provided, for example, that the coupling section or the head element or the contact lamellas contact the groove, in particular on at least two sides. This advantageously results in a further increase in the contact surface or the contact points between the lamella cage and the contact element. This increases the robustness against adverse operating conditions and reduces the contact resistance. As already described above, the groove has three surfaces or sides: an inner groove wall or groove inner side (which, for example, encloses an inner area in the case of a groove that runs in the direction of rotation in the contact element and/or runs around an optionally present centering part), an outer groove wall or groove outer side (which, for example, is formed radially outside the inner groove wall and, for example, runs closer to an edge of the contact element or its head section or which is closer to the outer wall of the contact chamber than the inner groove side) and a groove base or a base side. The groove base can, for example, extend transversely to the insertion direction.

It can be provided, for example, that the surfaces or sides of the groove contacted by the front section are rotated relative to one another by at least 30°. In the second position, for example, the groove base and the groove inner wall can be contacted by the coupling section or the head element or the contact lamellae or their front section, or the groove base and the groove outer wall or all three walls can be contacted by the coupling section or head element or contact lamellae.

In a further development, it is provided that in the second position the mechanical contact of the coupling section takes place through the groove bottom.

In other words: it is provided that in the second position the contact element with the groove bottom mechanically contacts the coupling section in such a way that the contacting sections of the contact lamellas are displaced along the radial direction towards the outer wall and thereby electrically contact a contact section of the outer wall and in particular clamp the lamella cage between the outer wall.

In other words: the groove base exerts a force acting essentially in the axial direction on the coupling section or on its front side. As a result, the contact lamellae are compressed in the axial direction and deviate radially in the contact section in the direction of the outer wall. As a result, the contact section of the outer wall is mechanically and electrically contacted by the contact sections of the contact lamellae and a defined contact norm is achieved. painting force is applied through the contact lamellas to an inner side of the outer wall.

This advantageously results in a particularly defined position of the mechanical contact of the coupling section.

Another advantage is that this creates axial contact between the laminar cage and the contact element, which is particularly robust against vibrations, thermal expansion, manufacturing tolerances, etc. that act in the radial direction.

In a further development, it is provided that an inner wall of the groove, in particular facing away from an outer edge of the underside, runs obliquely outwards towards a groove bottom.

In other words: when viewed from below, the groove has a funnel-shaped slope on the inside of the groove that is further away from the edge or the outer wall of the contact chamber.

This advantageously ensures that the contact blades (in particular with their contacting section) are not displaced in a radial direction solely due to an axial force acting on the front section by the contact element. Rather, the slope can create a type of guide rail through which the coupling section is moved or displaced in a targeted manner in the radial direction towards the outer wall. In this way, the displacement can be influenced in a targeted or more targeted manner. The shape of the slope can also advantageously create a type of path-force curve through which the translation of the axial path of the contact element into a radial path of the contact blades can be adjusted when the contact element is displaced from the first position to the second position. By adjusting the slope, the application of the normal force can advantageously be adapted to the given installation space situation and the available path from the first position to the second position.

In particular, the groove can run at an angle on the inner wall of the groove in such a way that a kind of (half) funnel shape can be seen when looking into the groove.

For example, a first angle of the groove inner wall with respect to the insertion direction can be in a range between 2° and 45° or in a range between 3° and 15°.

In a further development, it is provided that the groove has a funnel shape in cross section.

In other words: the groove inner wall and the groove outer wall both run at an angle and taper into the contact element.

For example, it can be provided that the groove has the shape of an inverted “V” or the shape of a “Y”, with the more open side of this shape facing the coupling section.

This has the advantage that the coupling section or the head element or the contact blades can be securely threaded into the groove even with positioning and/or manufacturing tolerances. This advantageously increases the manufacturing reliability when plugging together the connector and mating connector.

Another advantage is that this results in a larger contact surface and a higher number of contact points between the lamella cage and the contact element. If, for example, the coupling section or the head element or the contact lamellae are too large in relation to the width of the funnel at this point at the narrow point of the funnel, the coupling section or the head element or the contact lamellae are clamped in at the side and thus contacted. Here too, the funnel shape offers an advantage in terms of manufacturing tolerances. If, for example, the coupling section is too wide, insertion into the groove is not blocked or leads to damage to the groove and/or coupling section. Instead, the coupling section is inserted into the funnel-shaped groove until it reaches an excess in relation to the funnel shape and is clamped in place. Further axial displacement of the contact element is converted into further compression of the contact lamellae in the contact area and then increases the normal force there.

This ensures a particularly high level of manufacturing reliability as well as a particularly safe and reliable contact between the lamella cage and the contact element.

In a further development, it is provided that in the second position the coupling section is clamped between the groove inner wall and the groove outer wall, so that the coupling section electrically contacts both the groove inner wall and the groove outer wall.

This advantageously creates a particularly large contact surface between the laminar cage and the contact element. Another advantage of this method is that the contact is particularly robust against mechanical or thermal influences and/or manufacturing tolerances in the axial and radial directions.

According to a further aspect of the invention, a connector, in particular for high-current applications and/or high-voltage applications, is proposed.

The connector is suitable or designed for mating with a mating connector having a contact element. The connector has a lamella cage with a base element and with a plurality of contact lamellas. The contact lamellas are connected to the base element in a rear section; they protrude from the base element in the direction of the mating connector. The contact lamellas have a front section that faces the mating connector and that has a cantilevered end or through which the contact lamellas are connected to a head element of the lamella cage. The contact lamellas have a contacting section that is arranged between the rear section and the front section. The lamella cage has a coupling section, wherein the coupling section can be formed by the front section or by the head element only by way of example. The connector has a contact chamber with an outer wall. The lamella cage is arranged in the contact chamber. The contacting sections are curved in relation to the rear section and the front section, in particular in the force-free state (e.g. radially) in the direction of the outer wall.

The lamella cage is designed in such a way that when a force is applied along a plug-in direction to the coupling section (e.g. by a contact element of the mating connector) or by a displacement of the coupling section along the plug-in direction, which corresponds e.g. to a displacement of the contact element and/or the mating connector from the first position to the second position, the contacting sections of the contact lamellas are displaced along a radial direction towards the outer wall and the contacting sections thereby electrically contact a contact section of the outer wall and in particular clamp the lamella cage between the outer wall.

This provides the same advantages as described above for the connector arrangement.

drawings

Further features and advantages of the present invention will become apparent to those skilled in the art from the following description of exemplary embodiments, which, however, are not to be interpreted as limiting the invention, with reference to the accompanying drawings.

• 1: eine schematische perspektivische Ansicht einer Steckverbinderanordnung in einem nicht kontaktierten Zustand;
• 2a bis 2c: perspektivische schematische Ansichten von zwei unterschiedlichen Lamellenkäfigen eines Steckverbinders (2a und 2b) sowie eine Aufsicht auf ein Stanzblech (2c) als Ausgangszustand für einen Lamellenkäfig;
• 3a und 3b: schematische Querschnitte durch eine Steckverbinderanordnung mit dem Gegensteckverbinder in einer ersten Position (3a) bzw. in einer zweiten Position ( 3b);
• 4a und 4b: schematische Querschnitte durch zwei weitere Steckverbinderanordnungen mit dem Gegensteckverbinder in der zweiten Position;
• 5a und 5b: schematische Querschnitte durch eine weitere Steckverbinderanordnung mit dem Gegensteckverbinder in der ersten Position (5a) bzw. in der zweiten Position (5b).

Show it:

• 1 : a schematic perspective view of a connector arrangement in a non-contacted state;
• 2a to 2c : perspective schematic views of two different lamella cages of a connector ( 2a and 2 B) and a top view of a punching sheet ( 2c ) as the initial state for a lamella cage;
• 3a and 3b : schematic cross-sections through a connector arrangement with the mating connector in a first position ( 3a) or in a second position ( 3b) ;
• 4a and 4b : schematic cross-sections through two further connector arrangements with the mating connector in the second position;
• 5a and 5b : schematic cross-sections through another connector arrangement with the mating connector in the first position ( 5a) or in the second position ( 5b) .

1 shows a schematic perspective view of a connector arrangement 100 in a non-contacted state, eg in a pre-plug position. For reasons of clarity, neither an actuating element (such as a lever element or a slide element) for reducing the operating force when plugging together, nor a connector housing, nor a mating connector housing are shown here. Such elements are known from the prior art and do not represent essential elements for the feasibility of the invention.

The connector arrangement 100 is configured here merely as an example for high-current applications (e.g. for transmitting at least 10A, preferably at least 50A and particularly preferably at least 100A) and/or high-voltage applications (e.g. for at least 100V, preferably at least 200V and particularly preferably at least 500V).

The connector arrangement 100 has a connector 1 and a mating connector 2 for plugging together, here eg in particular along a plug-in direction E, with the connector 1, wherein a radial direction R runs perpendicular to the plug-in direction E and wherein a circumferential direction U runs around the plug-in direction E. The plug-in direction E can also be referred to as an axial direction. In other cases, it can also be referred to as a displacement direction of a contact element 9 described below with respect to of a lamella cage 3 described below during the contacting process.

The plug connector 1 has a lamella cage 3 with a base element 4 and with a plurality of contact lamellas 5. The contact lamellas 5 are connected to the base element 4 in a rear section 6. They protrude from the base element 4 in the direction of the mating connector 2 and they have a front section 7 which faces the mating connector 2 and through which - here as an example - the contact lamellas 5 are connected to a head element 40 of the lamella cage. In other embodiments, the contact lamellas 5 can, for example, have a self-supporting end 8 in the front section 6. The contact lamellas 5 also have a contacting section 41 which is arranged between the rear section 6 and the front section 7.

Furthermore, the lamella cage 3 has a coupling section 42. This is formed here only by way of example by the head element 40. In other embodiments, it can be formed, for example, by the front section 7.

The connector 1 further comprises a contact chamber 14 with an outer wall 15, wherein the lamella cage 3 is arranged in the contact chamber 14. The contacting sections 41 are curved in the direction of the outer wall 15 (here, for example: radially), in particular with respect to the rear section 6 and the front section 7.

The mating connector 2 has a contact element 9 with a bottom side 35 facing the lamella cage 3. The mating connector 2 and/or the contact element 9 is/are displaceable between a first position P1 and a second position P2, in particular when plugged together with the connector 1 (see 3a , 3b , 4a , 4b , 5a , 5b) , especially along the insertion direction E. At least up to the first position P1 (see 3a , 5a) the mating connector 2 and/or the contact element 9 can be displaced along the insertion direction E with a force of less than 5N, in particular force-free. In the second position P2 (see 3b , 4a , 4b , 5b) the contact element 9 mechanically contacts the coupling section 42 of the lamella cage 3 in such a way that the contact sections 41 of the contact lamellas 5 are displaced along the radial direction R towards the outer wall 15 and the contact sections 41 thereby electrically contact a contact section 13 of the outer wall 15. They can, for example, clamp the lamella cage 3 between the outer wall 15.

The first position P1 can be referred to as a pre-contact position or intermediate plug position - here the contact element 9 can already be loosely in mechanical contact with the coupling element 42, e.g. resting against it or arranged very close to the coupling element 42, e.g. less than 500um or less than 200um. The second position P2 can be referred to as a final contact position or final plug position, in which the electrical connection is formed in the desired state. A position as in 1 shown can be described as a pre-position, in which, for example, the first position has not yet been reached.

The contact chamber 14 can, for example, be electrically connected to the first component 50. Depending on the embodiment, it can also be mechanically connected to the first component 50, e.g. by a press-fit connection and/or a soldered connection or the like. The laminar cage 3 can, for example - in the first position P1 - be arranged loosely in the contact chamber 14, e.g. with play or a gap 29 (see 3a , 5a) to the outer wall 15.

The first component 50 can be designed, for example, as a circuit board 51 or as a busbar. It can also be connected directly to an electrical power component, e.g. an inverter, an AC/DC converter, a battery, an electrical machine or the like, or can be designed as such a power component. A particularly simple embodiment of a plug connector 1 is thus shown here. It is understood that in other embodiments the plug connector 1 can also have a plug connector housing in which the lamella cage 3 is arranged.

The contact element 9 here has, for example, a head element 10. It also has - purely by way of example - a centering part 11 with a (front) end 31 that protrudes from it in the direction of the lamella cage 3, whereby the centering part 11 can be omitted in other embodiments, it is not absolutely necessary here for electrical contact. The (front) end 31 of the centering part 11 is designed here purely by way of example as a self-supporting end. In this exemplary embodiment, the contact element 9 has a mushroom shape (a T-shape in longitudinal section). The centering part 11 preferably serves for radial centering of the contact element 9 relative to the lamella cage 3. It can (see 3a , 3b) also serve to radially stabilize the contact element 9 in the second position P2. It can basically be made of an insulating material.

The contact element 9 is here, for example, electrically connected to a second component 60, eg directly as shown here or via a line or via a busbar, etc. The second component 60 can eg be designed as a further power unit, eg as an inverter, an electrical machine, a battery, etc. The second component 60 can, however, also be a circuit board or a line which is connected to the further power unit.

The second position P2 can be reached starting from the first position P1, e.g. by an axial force acting on the contact element 9, in particular along the insertion direction E. The lamella cage 3 is mechanically contacted by this axial force acting or the axial pressure of the contact element 9 or the head part 10 or its underside 35 and the contact lamellae 5 deviate under this force acting at least partially (in particular in the radial direction R) towards the outer wall 15.

As a result, the contact lamellae 5 in the contact section 13 are pressed against the outer wall 15. The lamella cage 3 is compressed.

Thus, in the second position P2, the lamella cage 3 is contacted to the contact chamber 14 by the contacting sections 41 of the contact lamellas 3 and thus a reliable electrical connection of the lamella cage to the connector 1 or the first component 50 is achieved. At the same time, the coupling section 42 ensures a reliable and good electrical connection to the contact element 9 and thus to the mating connector 2 and to the second component 60.

The lamella cage 3 can be made, for example, from a material with good electrical conductivity, such as copper or a copper alloy. The contact lamellae 5 can be designed to be elastically reversible with respect to the displacement of the contact element 9 from the first position P1 to the second position P2. This means that when the contact element 9 is displaced back from the second position P2 to the first position P1 or even further, the contact lamellae 5 are displaced (approximately) back to their initial position, which they had assumed in the force-free initial state. A new plugging process can then take place, which in the second position P2 of the contact element 9 again leads to a displacement of the contact lamellae 5 radially towards the outer wall 15 of the contact chamber 14 and to an electrical contact being made therewith.

The insertion direction E can also be defined as the direction which is given by the direction of displacement of the contact element 9 when contacting the laminar cage 3.

In the 2a and 2 B perspective schematic views of two different lamella cages 3 of a connector 1 are shown.

2a shows a lamella cage 3 similar to 1 shown, in which the contact lamellae 5, starting from the base element 4, first pass into a rear section 6, from this into the contacting section 41, from this into the front section 7 and from this into the head element 40. In the rear section 6, the contact lamellae 5 are connected to the base element 4. In the front section 7, the contact lamellae 5 are connected to the head element 40. Head element 40 and base element 4 are closed in a ring shape, for example. They can have a circular, elliptical or polygonal cross-section, for example (here: circular). The contacting sections 41 of the contact lamellae 5 are clearly bulging radially outwards (towards the outer wall 15 of the contact chamber 14, not shown here). This bulging means that when the lamella cage 3 is axially compressed, the contact lamellae 5 bulge further outwards and are not indifferent with regard to a possible radially inner and radially outer bulge.

Due to the closed design of the lamella cage 3 at both distal ends (base element 4 and head element 40), an axial pressure on the coupling section 42, which is formed here by the head element 40 as an example, can be distributed particularly evenly across the contact lamellae 5. Another advantage of this is that when the lamella cages 3 are transported and handled as individual components during production, the risk of the lamella cages 3 (e.g. as bulk goods) becoming caught on one another or damaging one another is reduced.

2 B shows a lamella cage 3 similar to that of 2a , in which, however, the contact blades 5 have free ends 8 in their front section 7. Thus, here the coupling section 42 is formed by the front section 7 of the contact blades 5.

The free ends 8 form the front side 33 as an example. 2 B The lamella cage 3 shown is particularly easy to manufacture. The shape of the free end 8, which is slightly bent radially outwards, advantageously prevents the free ends 8 from digging into the underside 35 when an axial force is applied by the contact element 9. A sliding surface is provided which converts the axial force particularly easily into a radial movement of the contact lamellae 5 towards the outer wall 15 (here: radially outwards).

2c shows a top view of a stamped sheet as the initial state for a laminar cage 3 as in 1 and 2a , i.e. with base element 4 and head element 40. This is therefore ultimately a two-dimensional precursor to the lamella cage 3.

In 2c The base element 4 can be seen on the lower side and the majority of the contact blades 5 protruding upwards from it. The head element 40, to which the contact blades 5 are connected, is arranged on the upper side. 2c On the left side of the base element 4 and the head element 40, two pins 25, which are round in this example, can be seen, which are connected to the base element 4 by means of a neck area with a smaller diameter. 2c On the right-hand side of the base element 4 and the head element 40, two recesses 24 complementary to the pins 25 (also with a neck area) can be seen. In order to design the lamella cage 3, this two-dimensional punching form can first be pressed or embossed, for example, in such a way that the desired course of the contact lamellae 5 is obtained (e.g. the contact areas or contact sections 41 bulging radially outwards). The lamella cage 3 can then be formed by a winding process, wherein the pins 25 are latched or inserted into the recesses 24 and the lamella cage 3 is held dimensionally stable by means of the form-fitting connection of the base element 4 and the head element 40 formed here. In other embodiments, the base element 4 and/or the head element 40 can be connected in a material-to-material manner (e.g. soldered, welded, glued, etc.). In still other embodiments, the base element 4 and/or the head element 40 can simply be wound and/or embossed, for example, so that it automatically holds the predetermined shape, e.g. is formed in a closed ring shape.

The 3a to 5b show schematic cross sections through various connector arrangements 100. The mating connector 100 or the contact element 9 is in the first position P1 ( 3a and 5a) or in the second position P2 ( 3b , 4a , 4b and 5b) shown. One contact blade 5 can be seen to the left and one to the right of the centering part 11, which is only shown here as an example. The centering part 11 has a centering part outer wall 19.

The lamella cage 3 is e.g. in the 3a , 3b , 4a , 5a and 5b similar to the one from 1 and 2a (with head element 40). The lamella cage 3 of the 4b is similar to the one in 2 B (without head element 40, with free ends 8), whereby its free ends 8 can even be bent outwards. Basically, in all embodiments, lamella cages can be used similar to 2a or similar to 2 B be used.

In all embodiments shown, the laminar cage 3 can be arranged, for example, in the first position P1 loosely or with radial play in the contact chamber 14.

Furthermore, it can be seen schematically how the first component 50 is electrically connected to the connector 1 and the second component 60 is electrically connected to the mating connector 2. The 3a to 5b For reasons of clarity, no actuating element for reducing the insertion force is shown, even though such an actuating element (e.g. a lever element, a slide element or the like) can be provided optionally.

The contact element 9 has in the embodiment of the 3a and 3b on its underside 35 facing the coupling section 42 of the lamella cage 3, it has a substantially planar, flat or smooth surface.

In other embodiments, a groove 16, in particular a circumferential groove (see e.g. 4a , 4b , 5a and 5b) Such a groove 16 can, for example, have a funnel shape in cross section with an initially obliquely running groove inner wall 18 and groove outer wall 22, wherein the groove inner wall 18 and groove outer wall 22 then run essentially parallel and/or perpendicular to the groove bottom 30, e.g. in the manner of a “Y” shape (see 4a) . In particular, the groove inner wall 18 can, for example, have a first angle W1 with respect to the insertion direction E, which is different from zero. For example, the first angle W1 of the groove inner wall 18 with respect to the insertion direction E can be in a range between 2° and 45° or in a range between 3° and 15°.

Or the groove 16 may, for example, have a substantially vertical groove outer wall 22 and a substantially vertical groove inner wall 18, e.g. in the manner of a "U" shape or a rectangular shape (see 4b) or the groove 16 can have a groove outer wall 22 and a groove inner wall 18, each of which runs completely obliquely (i.e., each has an angle not equal to 0° to the axial direction), e.g. in the manner of a “V” shape (see 5a and 5b) .

In principle, it is also conceivable that such a groove 16 has a half-funnel shape, wherein in particular the groove inner wall 18 runs obliquely at least in sections (and e.g. has a first angle W1 as described above). Such a slope can not only achieve radial centering of the contact element 9 and facilitate insertion. Alternatively or additionally, the slope of the groove inner wall 18 can be used to displace the coupling region 42 radially towards the outer wall 15 on the way from the first position P1 to the second position P2 in the manner of a guide. This supports the application of the contact normal force to the outer wall 15 in addition to the compression of the contact lamellae 5 in the radial direction towards the outer wall 15.

Furthermore, it is also conceivable, for example, that the underside 35 is convexly curved, i.e. is higher at the edge 17 than in the middle area. In such a case, it can form a continuous surface without jumps (such as through a groove 16).

3a shows the first position P1 when plugging together the connector 1 and the mating connector 2. The contact element 9 here has a centering part 11, which already overlaps to a very large extent (almost 100%) with the lamella cage 3 (overlap along the insertion direction E). The underside 35 of the contact element 9 rests loosely on the front side 33, in this case on the head element 40, which here serves as a coupling section 42, for example. No or only a small axial force (e.g. only gravity) is exerted by the contact element 9 on the coupling section 42 and thus on the contact lamellae 5. It is also conceivable that in the first position P1 the underside 35 is still somewhat spaced (eg between 1 µm and 500 µm, preferably between 1 µm and 200 µm) from the front side 33 of the coupling section 42, so that no force is exerted in the axial direction.

The contact chamber 14 here also has, for example, a base 26. In the base 26 of the contact chamber 14, a base recess 27 is arranged, into which, for example, a front end 31 of the centering part 11 (here: a cantilevered end of the centering part 11) can be introduced (eg in the second position P2, see 3b) In this way, for example, with the aid of the centering part 11, the correct radial positioning of the contact element 9 in the second position P2 can be ensured or the positioning tolerances when plugging together can be reduced.

In 3a It can also be seen that at least up to the first position P1 the mating connector 2 or the contact element 9 can be displaced along the insertion direction E with a force of less than 5N, in particular without force, since up to the first position P1 there is no friction and no beak forces, etc. between the contact element 9 and the lamella cage 3, although a large part of the insertion path has already been covered. It can also be seen that in the first position P1 a radial play is formed between the contact lamellae 5 and the outer wall 15 of the contact chamber 14, here in the form of a gap 29.

The force-free displacement or the displacement with a force of less than 5N refers in particular to forces that are necessary to overcome frictional forces, beak forces, etc. Overcoming gravity, e.g. in the case of overhead installation, should not be taken into account here.

In the first position P1, for example, the radial play between the contact blades 5 and the outer wall 15 is in a range between 5um and 200um or in a range between 20um and 100um, e.g. at 20um or at 30um or at 40um or at 50um or at 60um or at 70um or at 80um or at 90um or at 100um or at 130um or at 160um or at 200um. In other words: the gap 29 causes the radial play and establishes a first distance D1 (in the radial direction R) in the range described above (e.g. between 5um and 200um, etc.).

3b shows the contact element 9 in the second position P2 (solid lines - the previous first position P1 from 3a is shown with dashed lines). The front end 31 of the centering part 11 is introduced into the bottom recess 27 of the bottom 26 of the contact chamber 14 or is arranged in the bottom recess 27. For this purpose, the bottom recess 27 can, for example, have a, in particular slight, oversize (e.g. up to 500 µm, preferably up to 250 µm) compared to the front end 31. However, a press fit can also be formed, ie that the front end 31 has a, in particular slight, oversize with respect to the diameter of the bottom recess 27. In this way, the contact element 9 is guided and/or secured in the radial direction 9, whereby a permanent and reliable contact is advantageously ensured even under adverse operating conditions (e.g. shaking loads, thermal cycling loads, etc.).

The first position P1 and the second position P2 are, for example, spaced apart along the insertion direction E by a maximum of 5 mm, preferably by a maximum of 2 mm and most preferably by a maximum of 1 mm.

In other words, the second position P2 is spaced from the first position P1 by a second distance D2 (viewed along the insertion direction E).

In the second position P2, the contact element 9 mechanically contacts the coupling section 42 of the lamella cage 3 in such a way that the contact lamellae 5 are displaced along the radial direction R towards the outer wall 15 and the contacting sections 41 thereby electrically contact the contact section 13 of the outer wall and in particular clamp the lamella cage between them (in particular viewed along the radial direction R).

In other words: the contact element 9 presses or presses by means of its underside 35 onto the front side 33 of the coupling section 42, whereby the contact lamellae 5 deflect or tilt or are tilted or are displaced or are displaced radially outwards or towards the outer wall in the radial direction R. As a result, the outer wall 15 in the contact section 13 is subjected to a contact normal force by means of the contact sections 41 of the contact lamellae 5, which here, for example, acts essentially in the radial direction R.

In this embodiment, it is provided by way of example that in the second position P2 the contact blades 5 contact the contact section 13 each with a contact normal force in the radial direction R of at least 1N, preferably of at least 5N.

In addition to the contact within the connector 1 (from the lamella cage 3 to the contact chamber 14), in the second position P2 an electrical contact is also established between the connector 1 and the mating connector 2, which extends via the front side 33 of the coupling section 42 to the underside 35 of the head section 10 of the contact element. This contact runs essentially along the axial direction.

Purely schematically, in the 3a and 3b Furthermore, an optional locking element 28 is shown, which secures the second position P2 against loosening. The locking element 28 is shown here only symbolically or schematically as a type of slider, which in the second position P2 can be guided through locking recesses 36 in the base 26 of the contact chamber 14 and in the area of the base recess 27 passes through a recess 32 in the centering part 11.

4a shows a schematic cross section through another connector arrangement 100 in the second position P2, this connector arrangement 100 being similar to that of 3b is trained.

In contrast to the 1 , 3a and 3b However, no centering part 11 is provided on the contact element 9, even if a centering part could be provided optionally (as in 1 , 3a , 3b the centering part 11 could optionally be dispensed with). The contact element 9 here only has the head section 10.

The connector assembly 100 of 4a However, it differs from that of 3b among other things, in that a groove 16 is made in the underside 35 of the contact element 9 on the side facing the lamella cage 3. This makes it possible, for example, to advantageously capture the front side 33 of the coupling section 42 and thus arrange it in the correct radial position on or in the underside 35, e.g. already in the first position P1. If, in an embodiment not shown here, in which the lamella cage 3 does not have a head element 40, one or more contact lamellas 5 are damaged or bent, for example if the front side 33 is not in the correct radial position, or if the contact element 9 is placed slightly radially offset, then a (particularly radial) self-centering of the bent contact lamella(s) 5 in the groove 16 can advantageously take place and/or a radial self-centering of the contact element 9 can take place. If there is a significant bend in one or more contact blades 5, the contact element 9 may become skewed because some contact blades 5 are caught in the groove 16, while others are outside on the underside 35. Such skewing can be used by a fitter or a machine as an indication of a problem. The assembly quality can thus be advantageously improved.

In the second position P2, the coupling section 42, here the head element 40, is arranged in the groove 16.

Due to the funnel shape of the groove 16 shown here, the coupling section 42 in the second position P2 is electrically contacted on at least two sides, e.g. the groove inner wall 18 and the groove outer wall 22. In this embodiment, the coupling section 42 in the second position is even electrically and mechanically contacted on three sides: on the groove bottom 30 (in the axial direction) and on the groove inner wall 18 and the groove outer wall 22 (each in the radial direction R).

The optional locking element 28 for securing the second position P2 is designed here merely as an example as a type of clamp which clamps the contact element 9 and the contact chamber 14 together and thus secures the connector 1 and the mating connector 2 against displacement apart.

4b shows a schematic cross-section through another connector arrangement 100 in the second position P2, this connector arrangement 100 being similar to that of 4a is formed, i.e. has a groove 16 in the head section 10.

Also in this embodiment, the contact element 9 does not have a centering part 11, even though it could be provided optionally.

Here, however, the groove 16 has a substantially rectangular cross-section (e.g. similar to a U-shape). In addition, the lamella cage 3 here, for example, does not have a head element 40, but rather the contact lamellae 5 are formed with free ends 8 in their front section 7.

It can also be seen that in this exemplary embodiment, the contact blades 5 in the front section 6 are bent outwards in the radial direction R (or in the direction of the outer wall 15, whereby the outer wall 15 is less high than the blade cage 3). Here, for example, they are bent relative to the insertion direction E by a second angle W2, which here is, for example, somewhat larger than 180° and can be in a range between 185° and 260°, for example only. The second angle W2 can also be omitted entirely in other exemplary embodiments or it can be, for example, at least 30°, preferably at least 60° and particularly preferably at least 110°.

In this exemplary embodiment, in the second position P2, the contact blades 5 are arranged with their front sections 6 in the groove 16, with the front sections here forming the coupling section 42, for example. In this way, the contact blades 5 are advantageously secured against (radially) slipping out of the contact position, e.g. even in the case of strong vibration loads or thermal cycling. It cannot therefore easily happen that the front side 33 is briefly displaced radially outwards (e.g. due to an impact) and the contact blade 5 thereby changes its bend (e.g. into a bistable second state in which the contact blade 5 folds over radially inwards at the level of the contact section 13).

In this exemplary embodiment, the contact blades 5 contact the groove 16 on at least two sides. The at least two sides are preferably spaced apart from each other by at least 30° (this is an angle in the illustrated image plane, not an angle along the circumferential direction U). One contact side is, for example, the groove inner wall 18. Another contact side is, for example, the groove bottom 30. In this exemplary embodiment, the contact blade 5 also contacts the groove outer wall 22. The front section 6 of the contact blades 5 is pressed together in the groove 16 in the second position P2 due to the axial force exerted by the contact element 9 and fills the groove 16 significantly more in the second position P2 than in the first position P1. In this way, the contact area between the contact blades 5 and the contact element 9 is considerably enlarged, whereby the current-carrying capacity of the connector arrangement 100 (significantly) increases and the contact resistance decreases. Furthermore, the number of contact points is advantageously increased in this way. This advantageously increases the redundancy at contact points so that the connector assembly 100 is better protected against failures.

The optional locking element 28 for securing the second position P2 is shown here only as an example as in 4a designed as a kind of bracket.

In this exemplary embodiment, the groove 16 runs obliquely outwards on the groove inner wall 18 towards the groove base 30. In addition to the radial tilting or displacement of the contact blades 5 caused by the axial force or compression (by the contact element 9), this displacement or tilting can be supplemented or supported by a positive-locking component. The oblique groove inner wall 18 acts like a guide or a guide rail, which causes a strictly defined radial displacement of the front section 7 of the contact blades 5 in the radial direction R towards the outer wall 15 when the contact element 9 moves axially along the insertion direction E.

In this exemplary embodiment, it is provided that the first angle W1 of the groove outer wall 22 with respect to the insertion direction E is in a range between 2° and 45° (i.e. a range of 2°-45°) or in a range between 3° and 15° (i.e. a range of 3°-15°).

As a result, when the contact element 9 is moved from the first position P1 to the second position P2 (i.e. by a distance corresponding to the second distance D2, see 3a and 3b) In addition to the axial force, it is ensured that the contact blades 5 move a defined distance in the radial direction R towards the outer wall 15 and that the desired contact normal force in the contact section 13 of the outer wall 15 is thereby applied by the contact blades 5 or their contact sections 41. Furthermore, it is ensured that a gap 29 optionally present in the first position P1 (see 3a) between contact blades 5 and outer wall 15. Another advantage is This also increases the contact area between the coupling section 42 and the contact element 9, thereby improving the electrical contact between the lamella cage 3 and the contact element 9.

The optionally present locking element 28 is in the exemplary embodiment of 4b analogous to the locking element from 4a formed (as a kind of bracket).

The 5a and 5b show schematic cross sections through a further connector arrangement 100 with the mating connector 2 in the first position P1 ( 5a) or in the second position P2 ( 5b) .

The contact element 9 is accommodated or arranged in a mating connector housing 61. It is here, for example, mounted or arranged on its head section 10 in a contact element chamber 62 and preferably secured with respect to the axial direction. This mounting can also secure it against tilting, for example. In this exemplary embodiment, the contact element

In the cross section shown, two locking elements 52 can be seen that are spaced apart from one another and are arranged on the first component 50 and protrude from the first component 50 in the direction of the mating connector 2. The lamella cage 3 is arranged between them. The locking elements 52 have undercuts here, for example.

In the cross section shown, two counter-latching elements 63 can be seen on the mating connector housing 61, which protrude from the mating connector housing 61 in the direction of the connector 1 and each have a hook element. The counter-latching elements 63 can be designed in the form of elastically reversible latching lances or clip elements (in particular along the radial direction R). The contact element 9 is arranged between the counter-latching elements 63.

In the 5a In the first position P1 shown, the counter-latching elements 63 can rest on the latching elements 52 and thus advantageously provide a fitter with haptic feedback for reaching the first position P1. In other embodiments, it can be provided, for example, that a captive connection between the connector 1 and the counter-connector 2 is formed when the first position P1 is reached (or even before it is reached), so that the assembly can be transported in this state.

The counter-latching elements 63 can, for example, slide past the undercuts of the latching elements 52 on the way from the first position P1 to the second position P2 (deflection radially outwards in the exemplary embodiment shown) and in the second position P2 can be elastically reversibly spring back into their starting position radially inwards so that they engage behind the undercuts of the latching elements 52 with their hook elements. In this way, an unintentional release of the contact element 9 from the second position P2 in the direction of the first position P1 is prevented. Latching elements 52 and counter-latching elements 63 thus form a type of locking element 28.

The lamella cage 3 is exemplary analogous to the lamella cage from 2a formed. The underside 35 here has, for example, a groove 16 in which the groove inner wall 18 and the groove outer wall 22 are both formed at an angle and run towards each other. A kind of funnel shape is formed. Here, the groove is formed, for example, in the form of a "V" shape.

The lamella cage 3 has in the first position P1 ( 5a) for example, a radial clearance with respect to the outer wall 15, here, for example, a gap 29 is formed (with the first distance D1) between the outer wall 15 and at least one contact blade 5. In the second position P2 ( 5b) the contact lamellae 5 are in (mechanical) contact with the underside 35 or the groove 16 of the contact element 9 on or in their coupling section 42 (here: the head element 40). They are compressed by the axial force of the contact element (between the underside 35 and the base element 4 or between the head element 40 and the base element 4) and are thus displaced in the radial direction R towards the outer wall 15, which they electrically contact in the contact section 13 and in particular apply a defined contact normal force to. The lamella cage 3 can thus be clamped between the outer wall 15.

QUOTES INCLUDED IN THE DESCRIPTION

This list of documents listed by the applicant was generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions.

Cited patent literature

• DE 102018202960 A1 [0005]
• DE 102017213093 A1 [0006]
• DE 102019131791 A1 [0007]
• DE 202008005394 U1 [0008]
• WO 2007107208 A1 [0009]

Claims (11)

Connector arrangement, in particular for high-current applications and/or high-voltage applications, the connector arrangement (100) comprising: -- a connector (1); -- a mating connector (2) for plugging together with the connector (1); wherein the plug connector (1) has a lamella cage (3) with a base element (4) and with a plurality of contact lamellas (5), wherein the contact lamellas (5) -- are connected to the base element (4) in a rear section (6), -- protrude from the base element (4) in the direction of the mating connector (2) and -- have a front section (7) which faces the mating connector (2) and which has a cantilevered end (8) or through which the contact lamellas (5) are connected to a head element (40) of the lamella cage (3), -- have a contacting section (41) which is arranged between the rear section (6) and the front section (7), wherein the lamella cage (3) has a coupling section (42), wherein the plug connector (1) has a contact chamber (14) with an outer wall (15), wherein the lamella cage (3) is arranged in the contact chamber (14), wherein the contacting sections (41) are curved in relation to the rear section (6) and the front section (7) in the direction of the outer wall (15), wherein the mating connector (2) has a contact element (9) with a bottom side (35) facing the lamella cage (3), wherein the contact element (9) and/or the mating connector (2), in particular when plugged together with the connector (1), can be displaced between a first position (P1) and a second position (P2), in particular along an insertion direction (E), wherein at least up to the first position (P1) the contact element (9) and/or the mating connector (2) can be displaced with a force of less than 5N, in particular without force, along the insertion direction (E), wherein in the second position (P2) the contact element (9) engages the coupling section (42) of the lamella cage (3) in such a way mechanically contacted in that the contacting sections (41) of the contact lamellas (5) are displaced along a radial direction (R) towards the outer wall (15) and the contacting sections (41) thereby electrically contact a contact section (13) of the outer wall (15) and in particular clamp the lamella cage (3) between the outer wall (15). Connector arrangement according to the preceding claim, wherein in the second position (P2) the contact blades (5) contact the contact section (13) each with a contact normal force in the radial direction (R) of at least 1N, preferably of at least 5N. Connector arrangement according to one of the preceding claims, wherein the base element (4) and/or the head element (40) of the lamella cage (3) is designed to be circumferentially closed, in particular annularly closed. Connector arrangement according to one of the preceding claims, wherein the first position (P1) and the second position (P2) along the insertion direction (E) are spaced apart by at most 5 mm, preferably by at most 2 mm and particularly preferably by at most 1 mm. Connector arrangement according to one of the preceding claims, wherein in the first position (P1) the radial play between the contacting section (41) and the outer wall (15) is in a range between 5 µm and 200 µm or in a range between 20 µm and 100 µm. Connector arrangement according to one of the preceding claims, wherein a groove (16) with an inner groove wall (18), a groove base (30) and an outer groove wall (22) is introduced into the underside (35) of the contact element (9) for receiving the coupling section (42), in particular wherein in the second position (P2) the coupling section (42) is arranged in the groove (16), wherein the coupling section (42) contacts the groove (16) in particular on at least two sides. Connector arrangement according to the preceding claim, wherein in the second position (P2) the mechanical contacting of the coupling section (42) takes place through the groove bottom (30). Connector arrangement according to one of the two preceding claims, wherein a groove inner wall (18), in particular facing away from an outer edge (17) of the underside (35), runs obliquely outwards towards a groove bottom (30), wherein in particular a first angle (W1) of the groove inner wall (18) with respect to the insertion direction (E) lies in a range between 2° and 45° or in a range between 3° and 15°. Connector arrangement according to one of the three preceding claims, wherein the groove (16) has a funnel shape in cross section. Connector arrangement according to one of the four preceding claims, wherein in the second position (P2) the coupling section (42) between the groove inner wall (18) and the groove outer wall (22) is clamped so that the coupling section (42) electrically contacts both the groove inner wall (18) and the groove outer wall (22). Plug connector, in particular for high-current applications and/or high-voltage applications, for plugging together with a mating connector (2) having a contact element, wherein the plug connector (1) has a lamella cage (3) with a base element (4) and with a plurality of contact lamellas (5), wherein the contact lamellas (5) -- are connected to the base element (4) in a rear section (6), - protrude from the base element (4) in the direction of the mating connector (2) and -- have a front section (7) which faces the mating connector (2) and which has a cantilevered end (8) or through which the contact lamellas (5) are connected to a head element (40) of the lamella cage (3), -- have a contacting section (41) which is arranged between the rear section (6) and the front section (7), wherein the lamella cage (3) has a coupling section (42), wherein the plug connector (1) has a contact chamber (14) with an outer wall (15), wherein the lamella cage (3) is arranged in the contact chamber (14), wherein the contacting sections (41) are curved in relation to the rear section (6) and the front section (7) in the direction of the outer wall (15), wherein the lamella cage (3) is designed such that when a force is applied along an insertion direction (E) to the coupling section (42), in particular by the contact element, the contacting sections (41) of the contact lamellas (5) are displaced along a radial direction (R) towards the outer wall (15) and the contacting sections (41) thereby electrically contact a contact section (13) of the outer wall (15) and in particular clamp the lamella cage (3) between the outer wall (15).

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