EP3886263A1 - Elektrischer leistungsverbinder und verfahren zum zusammenbau eines solchen verbinders - Google Patents

Elektrischer leistungsverbinder und verfahren zum zusammenbau eines solchen verbinders Download PDF

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Publication number
EP3886263A1
EP3886263A1 EP20166086.7A EP20166086A EP3886263A1 EP 3886263 A1 EP3886263 A1 EP 3886263A1 EP 20166086 A EP20166086 A EP 20166086A EP 3886263 A1 EP3886263 A1 EP 3886263A1
Authority
EP
European Patent Office
Prior art keywords
rear grid
cavity
housing
power terminal
grid
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP20166086.7A
Other languages
English (en)
French (fr)
Inventor
Erwan Guillanton
Aymeric PEROT
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Aptiv Technologies Ltd
Original Assignee
Aptiv Technologies Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Aptiv Technologies Ltd filed Critical Aptiv Technologies Ltd
Priority to EP20166086.7A priority Critical patent/EP3886263A1/de
Publication of EP3886263A1 publication Critical patent/EP3886263A1/de
Withdrawn legal-status Critical Current

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/40—Securing contact members in or to a base or case; Insulating of contact members
    • H01R13/42—Securing in a demountable manner
    • H01R13/436—Securing a plurality of contact members by one locking piece or operation
    • H01R13/4367—Insertion of locking piece from the rear
    • H01R13/4368—Insertion of locking piece from the rear comprising a temporary and a final locking position
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/20—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for assembling or disassembling contact members with insulating base, case or sleeve

Definitions

  • the disclosure generally relates to the field of automotive connectors and more particularly to the field of power connectors for automotive vehicles. This disclosure also relates to a method for assembling such connectors. This disclosure relates for example to an inlet or socket connector such as those used for charging batteries of electric vehicles or plug-in hybrid vehicles.
  • electric vehicles or plug-in hybrid vehicles 100 may comprise a connector base or inlet or socket 200 on which a charge plug 300 powered by an electric charging station 400 can be connected via a cable 500.
  • This charge plug 300 then makes it possible to charge battery cells on board of the vehicle 100.
  • the connector 200 comprises a housing made of dielectric material and terminals each respectively accommodated in a cavity formed in the housing.
  • the terminals of such connectors are mounted in a separate module which is tightly screwed on the housing of the connector 200.
  • the screws allow for a precise positioning of the module relatively to the housing.
  • the module and the connector housing are supplied separately and the vehicle manufacturers have to assemble them.
  • the screwing operation is time consuming and may be difficult when there is not much room around the back side of the connector 200.
  • This disclosure aims at contributing to mitigate, at least partially, problems such as those mentioned above, encountered with connectors of the prior art.
  • the present disclosure provides an electrical connector according to claim 1.
  • the electrical connector of the present disclosure facilitates improved assembly.
  • the connector can be supplied with the rear grid already attached in the delivery position.
  • the terminals (possibly previously electrically and mechanically connected to a respective cable) can be then inserted in a respective cavity, and the rear grid is pushed from the delivery position to a closed position where the terminals are locked into their respective cavity, so as to prevent each power terminal from being removed from its cavity.
  • the disclosed connector may also optionally include one and / or the other of the features of any one of claims 2 to 10.
  • the disclosure also relates to a method for assembling a connector according to claim 11.
  • the power connector 200 shown on FIG. 2 is designed to be mounted in a vehicle 100.
  • the embodiment of the power connector 200 shown on FIG. 2 comprises a front face 201 from which two connecting interfaces 2, 3 are accessible.
  • Such a connector is also known as a Combo socket. It allows AC charging through a first interface 2 and fast DC charging through a second interface 3.
  • the power connector 200 shown on FIG. 2 is protected by a door which is not shown.
  • the power connector 200 comprises a housing 4 which can be made of one or more components moulded from dielectric material.
  • the housing 4 comprises an outer housing 6 and an inner housing 7 (See FIG. 2 ).
  • the inner housing 7 comprises cavities 5 for accommodating male power terminals 8, as well as signal terminals 13.
  • the male power terminals 8 are connected to cables or wires arranged in a single charging cable 500.
  • the inner housing 7 forms a sealed box with a cover (only a cover interface 9 is shown on FIG. 3 ).
  • a cover seal 10 is provided between the inner housing 7 and the cover interface 9 and a mat seal 11 is provided between the male power terminals 8 and the inner housing 7 (See FIG. 3 ).
  • the power connector 200 also comprises a printed circuit board 12 onto which the signal terminals 13 are mounted, as well as a rear grid 14.
  • the outer housing 6, the inner housing 7, the cover seal 10, the mat seal 11, the printed circuit board 12 with its signal terminals 13 and the rear grid 14 are delivered all together in the form of a sub-assembly.
  • the cavities 5 extend in a longitudinal direction L from a front opening 15 (see FIG. 2 ) to a rear opening 16 (see FIG. 4 ).
  • the rear opening 16 of a cavity 5 has dimensions equal or greater than that of the largest cross-section of the portion of the power terminal 8 inserted, from the rear opening 16, into this cavity 5. In other words, these dimensions allow for the insertion of a portion of the power terminal 8 in the cavity 5.
  • the portion of each power terminal 8 inserted in a respective cavity 5 includes a contact portion, i.e. the portion of a power terminal 8 designed to be mated with a female power terminal of a counter-connector (e.g. a plug connector).
  • Each power terminal 8 comprises an annular groove 17 in an intermediate portion located between the contact portion of the power terminal 8 inserted into a cavity 5 and a fixation portion of the terminal 8, the fixation portion being designed to be electrically and mechanically connected (for example by crimping) to a cable or wire.
  • the groove 17 has a gutter shape with two lateral annular walls 18 facing each other (see FIG. 9 ).
  • Each annular wall 18 extends in a plane perpendicular to the longitudinal direction L (i.e. the longitudinal direction of both the cavity 5 and the terminal 8).
  • One of the annular walls 18 is located closer to the rear opening 16 of the cavity 5. This annular wall 18 forms a stop 21 against which the rear grid 14 abuts, when the rear grid 14 is in its closed position (see FIG. 14 ), so as to prevent the power terminal 8 from being pulled out from this cavity 5.
  • the rear grid 14 comprises a panel 19 extending essentially in a plane perpendicular to the longitudinal direction L.
  • the panel 19 has five apertures 20 for the passage of a portion of a respective power terminal 8 inserted into a cavity 5.
  • each one of the apertures 20 is generally aligned, in the longitudinal direction L, with a rear opening 16.
  • Each one of the apertures 20 has a closed edge 22.
  • the closed edge 22 of each aperture 20 comprises two regions.
  • a first region 23 of the closed edge 22 has an arc-of-circle shape with a first radius of curvature.
  • a second region 23 of the closed edge 22 has an arc-of-circle shape with a second radius of curvature.
  • the second radius of curvature is less than the first radius of curvature. More particularly, the first radius of curvature is such that it does not prevent the passage of the largest cross-section of the portion of the power terminal 8 inserted, from a rear opening 16, into a cavity 5. On the contrary, the second radius of curvature is such that it limits the movement of the portion of the power terminal 8 inserted into the corresponding cavity 5, so as to prevent the terminal 8 from being pulled out from this cavity 5.
  • the rear grid 14 has a front face 25 and a back face 26.
  • the panel 19 On the front face 25 of the rear grid 14, around each one of the five apertures 20, the panel 19 has a first surface 27 and a second surface 28. Both the first 27 and second 28 surfaces are on the front face 25.
  • the first surface 27 runs essentially along the first region 23.
  • the second surface 28 runs essentially along the second region 24.
  • the first surface 27 is disposed rearward relatively to the second surface 28.
  • the second surface 28 partially faces and closes the rear opening 16 of the corresponding cavity 5.
  • the rear grid 14 has an interlocking thickness between the second surface 28 and its back face 26.
  • the width of the groove 17 between the two annular walls 18 corresponds essentially to the interlocking thickness so that the rear grid 14 is engaged in an adjusted manner in the groove 17, when the rear grid 14 is in the closed position.
  • one of the annular walls 18 abuts the second surface 28 and the other annular wall abuts against the back face 26 of the rear grid 14 (See FIG. 14 ).
  • the rear grid 14 comprises first locking means 29.
  • the first locking means 29 comprises four flexible legs 30 extending essentially in the longitudinal direction L.
  • the rear grid 14 comprises two flexible legs 30 on each one of its lateral sides.
  • the stiffness of the rear grid 14 and the symmetrical distribution of the flexible legs 30 on each one of its lateral sides ensure a reliable and precise positioning of the rear grid 14 relative to the inner housing 7.
  • Each flexible leg 30 extends from an end linked to the rear grid 14 to a free end provided with a hook 31.
  • Each hook 31 has a locking surface perpendicular to the longitudinal direction L and directed rearward.
  • each hook 31 engages an edge 32 of an aperture 33 made in a peripheral flange 34 of the inner housing 7 (See FIG.s 7 and 13 ).
  • the rear grid 14 is attached on the inner housing 7 in pushing the rear grid 14, along the longitudinal direction L, with the panel 19 essentially perpendicular to the longitudinal direction L, toward the back side 202 of the connector 200 until each hook 31 is clipped into a corresponding aperture 33.
  • Each aperture 33 has a first edge 35, a second edge 36 and a ramp portion 37 in between (See FIG. 13 ). The first edge 35 is located further back than the second edge 36.
  • each hook 35 slides on the ramp portion 37 and engages the second edge 36 (See FIGs. 11 and 12 ), so as to move the rear grid 14 closer to rear openings 16 of the cavities 5.
  • the rear grid 14 is moved from its delivery position to its closed position in pushing on actuating surfaces 38, in a top-down sliding direction TD on the drawings.
  • This movement of the rear grid 14 has both a component parallel to the longitudinal direction L and perpendicular to the longitudinal direction L.
  • the rear grid 14 comprises second locking means 39 for locking the rear grid 14 in its closed position (See FIG. 5 ).
  • the second locking means 39 comprises one flexible leg 40 on each one of its lateral sides.
  • Each flexible leg 40 extends from an end linked to the rear grid 14 to a free end provided with a hook 41.
  • Each hook 41 has a locking surface parallel to the longitudinal direction L and perpendicular to the sliding direction (TD direction) of the rear grid 14 from its delivery position to its closed position.
  • TD direction sliding direction
  • the apertures 20 are moved downwardly (See FIGs 6 and 10 ). In other words, the rear grid 14 is moved so that each second region 24 of the edges 22 inserts into a respective groove 17. Since the rear grid 14 is precisely secured on the inner housing 7 thanks to the first locking means 29, and since the power terminals 8 are precisely positioned thanks to the interaction between the rear grid 14 and the annular grooves 17, the power terminals 8 are precisely positioned with regard to the inner housing 7.
  • the gap measured parallel to the longitudinal direction L, between the outermost edge of a cavity 5 and the outermost electrically conductive portion of a power terminal 8 accommodated in this cavity 5 may be between 11.015 millimetres and 11.485 millimetres.
  • the mat seal 11 is mounted, inside the peripheral flange 34 of the inner housing 7, between the back side of the inner housing 7 and the printed circuit board 12.
  • the rear grid 14 has two posts 43, each one of which is located on a lateral side of the rear grid 14 and extending from its front face 25 in planes parallel to both the longitudinal direction L and the sliding direction TD (See FIG. 5 ). When the rear grid 14 is pushed from its delivery position to its closed position, the rear grid is moved downwardly and forwardly so that the posts 43 press the mat seal against the rear side of the inner housing 7.
  • the printed circuit board 12 is mounted, inside the peripheral flange 34 of the inner housing 7, between the mat seal 11 and the rear grid 14.
  • the outer housing 6, the inner housing 7, the mat seal 11, the cover seal 10 and the printed circuit board 12 are fitted one inside the other.
  • the rear grid 14 is attached to the inner housing 7 with the first locking means 29.
  • the rear grid 14 maintains in particular the inner housing 7, the mat seal 11 and the printed circuit board 12 all together.
  • This assembly can be supplied to a vehicle manufacturer.
  • power terminals 8 are inserted into their respective cavities 5 and an operator presses downwardly on the actuating surfaces 38 and pushes the rear grid 14 from the delivery position to the closed position. If one or several power terminals 8 are not properly inserted into a cavity 5, the sliding movement of the rear grid 14 is blocked by this or these terminals and the rear grid 14 cannot be placed in the closed position.
  • the rear grid 14 acts as a terminal position assurance device (TPA). When every power terminal 8 is properly and fully inserted, the rear grid 14 can be pressed down and inserted in the annular grooves 17, the interlocking thickness being adjusted to the groove width.
  • TPA terminal position assurance device

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Connector Housings Or Holding Contact Members (AREA)
EP20166086.7A 2020-03-26 2020-03-26 Elektrischer leistungsverbinder und verfahren zum zusammenbau eines solchen verbinders Withdrawn EP3886263A1 (de)

Priority Applications (1)

Application Number Priority Date Filing Date Title
EP20166086.7A EP3886263A1 (de) 2020-03-26 2020-03-26 Elektrischer leistungsverbinder und verfahren zum zusammenbau eines solchen verbinders

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP20166086.7A EP3886263A1 (de) 2020-03-26 2020-03-26 Elektrischer leistungsverbinder und verfahren zum zusammenbau eines solchen verbinders

Publications (1)

Publication Number Publication Date
EP3886263A1 true EP3886263A1 (de) 2021-09-29

Family

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EP20166086.7A Withdrawn EP3886263A1 (de) 2020-03-26 2020-03-26 Elektrischer leistungsverbinder und verfahren zum zusammenbau eines solchen verbinders

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EP (1) EP3886263A1 (de)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20220242259A1 (en) * 2021-02-04 2022-08-04 TE Connectivity Services Gmbh Terminal position assurance device for a charging inlet assembly
DE102021111250A1 (de) 2021-04-30 2022-11-03 Te Connectivity Germany Gmbh Anordnung zur Sicherung einer Leiterplatte an einem Steckerkörper, Verfahren zur Sicherung einer Leiterplatte an einem Steckerkörper

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5941737A (en) * 1997-02-10 1999-08-24 Yazaki Corporation Double retaining connector
US20150087190A1 (en) * 2012-06-01 2015-03-26 Tyco Electronics Amp Gmbh Electrical Connector
US10263356B2 (en) * 2017-05-12 2019-04-16 Tyco Electronics (Shanghai) Co. Ltd. Secondary lock and receptacle
US20190173221A1 (en) * 2017-12-01 2019-06-06 Te Connectivity Corporation Electrical connector with terminal position assurance member

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5941737A (en) * 1997-02-10 1999-08-24 Yazaki Corporation Double retaining connector
US20150087190A1 (en) * 2012-06-01 2015-03-26 Tyco Electronics Amp Gmbh Electrical Connector
US10263356B2 (en) * 2017-05-12 2019-04-16 Tyco Electronics (Shanghai) Co. Ltd. Secondary lock and receptacle
US20190173221A1 (en) * 2017-12-01 2019-06-06 Te Connectivity Corporation Electrical connector with terminal position assurance member

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20220242259A1 (en) * 2021-02-04 2022-08-04 TE Connectivity Services Gmbh Terminal position assurance device for a charging inlet assembly
US11919409B2 (en) * 2021-02-04 2024-03-05 Te Connectivity Solutions Gmbh Terminal position assurance device for a charging inlet assembly
DE102021111250A1 (de) 2021-04-30 2022-11-03 Te Connectivity Germany Gmbh Anordnung zur Sicherung einer Leiterplatte an einem Steckerkörper, Verfahren zur Sicherung einer Leiterplatte an einem Steckerkörper
JP2022171604A (ja) * 2021-04-30 2022-11-11 ティーイー コネクティビティ ジャーマニー ゲゼルシャフト ミット ベシュレンクテル ハフツンク プリント回路基板をプラグ本体に固定するためのアセンブリ、プリント回路基板をプラグ本体に固定する方法
DE102021111250B4 (de) 2021-04-30 2023-03-16 Te Connectivity Germany Gmbh Anordnung zur Sicherung einer Leiterplatte an einem Steckerkörper, Verfahren zur Sicherung einer Leiterplatte an einem Steckerkörper
JP7400004B2 (ja) 2021-04-30 2023-12-18 ティーイー コネクティビティ ジャーマニー ゲゼルシャフト ミット ベシュレンクテル ハフツンク プリント回路基板をプラグ本体に固定するためのアセンブリ、プリント回路基板をプラグ本体に固定する方法

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