EP4211755B1 - Cable connector for motor vehicles - Google Patents

Description

The subject matter relates to a cable connector for motor vehicles and a method for producing a cable connector.

As the electrification of automobiles increases, ever higher currents are being transmitted in vehicles. This is usually done via electrical cables. Cable connectors are also used to enable connections between a component such as power electronics, a battery, a motor, etc. and cables, as well as connections between a first cable and a second cable.

So-called connectors are widespread. Well-known connectors in the automotive sector are mostly based on spring contacts. In such spring-loaded connectors, a first and a second current-carrying base body, usually made of metal, are connected/clamped with a spring arranged between them. The restoring force of the spring enables the spring element to make permanent mechanical and electrical contact with the two base bodies. These often very thin springs are designed in such a way that they have many point-shaped projections at least on a contact surface that lies against a base body, where the mechanical and electrical connection is made. The electrical current flows between the spring and the base body at the contact points. Due to the limited area of such a relief surface, the contact resistance increases and Joule heating of the transition occurs. An increase in the current-carrying capacity or a reduction in the contact resistance and thus also in the power loss is achieved with such a design almost exclusively by increasing the number of contact points. The selection of the spring material also represents a challenge in the case of Spring-loaded connectors always represent a compromise between electrical conductivity and mechanical properties such as Young's modulus or relaxation.

In addition to conducting electrical energy, the cables in today's vehicles are also increasingly used to conduct heat, not least because of the good thermal conductivity of their electrical conductor materials such as copper and aluminum. Cables are therefore often an essential part of heat management in vehicles. A coupling between two cables or between cables and electrical components as well as between electrical components among themselves, e.g. between battery cell connectors or between battery module connectors among themselves or with a battery cell, a so-called flying coupling, therefore has the task of conducting heat as well as conducting current. However, connectors are not well suited to this because such transitions in the cable harness often generate additional unwanted heat through Joule losses. In addition, heat transfer is hindered by the often thin spring components. Worse still, the low heat capacity of the thin springs due to their design can lead to rapid heating, which in the worst case can cause cable fires.

Screw connectors are far better suited to heat transfer. In this case, comparatively large surfaces of two base bodies are pressed together with a force generated by a thread. The large-area contact reduces the ohmic resistance and increases the thermal conductivity. Screw connectors also usually have a large thermal mass compared to plug connectors. They therefore heat up more slowly than thin springs when exposed to high instantaneous currents. In this way, they ensure a low risk of overheating with the sluggish thermal behavior of the connection. Such a large thermal mass and high thermal conductivity is particularly necessary in the power train of electric vehicles, where high currents can occur during braking (via recuperation), acceleration or high-current charging.

The disadvantage of a screw connection, however, is that screwing is a more complex assembly step than plugging in, which takes longer and is more prone to errors. This is particularly problematic in view of the increasing automation of production in the field of electromobility. The increased time required to assemble screw connections makes them unattractive for automated production. For example, in the manufacture of high-current batteries, where a large number of battery cells and battery modules have to be contacted with one another, the large number of screw connections means a considerable amount of assembly work. In addition, screw connectors can cause problems due to defective threads or similar, which is why some screw connectors already use contact parts with two screw elements next to each other in order to reduce the susceptibility to errors/error rates. This leads to further assembly work.

The publication US$5,174,777 refers to an electrical connector system. The publication EN 10 2011 018 353 A1 relates to a connection of an electrical cable consisting of several wires or strands with a connector.

Based on this state of the art, the object was designed to combine the advantages of a screw connection with those of a plug connection. To do this, large surfaces are to be pressed together with high normal forces in order to generate good electrical and thermal conductivity. Furthermore, the connector should have a large heat capacity in order to be able to absorb a lot of heat energy and not heat up quickly. Another focus is on assembly, which should be quick, reproducible and as easy to automate as possible.

This object is achieved by a connector according to claim 1 and by a manufacturing method according to claim 15.

The connector in question comprises a first metal part and a second metal part. The metal parts can consist in particular of copper or a copper alloy and/or aluminum or an aluminum alloy. For example, high-strength aluminum alloys such as EN AW 6082 can be used. Other materials such as other metals or alloys thereof, such as steel, silver, gold, lead, etc. can also be used, or other conductors such as polymers, semiconductors, or similar. Combinations of non-conductors and conductors can also be used, in which conductors are arranged at least on contact surfaces described later and the non-conductors perform purely mechanical functions. Combinations of different, better and worse conductive materials, such as different metals, for example copper and steel, can also be combined. In this way, good conductivity on the one hand and high mechanical stability on the other can be achieved at reduced costs compared to a pure-type production.

The two metal parts can be made of the same material, in particular the same metal material. This has the advantage that contact corrosion caused by different redox potentials of different metals is excluded. Another advantage is that there are no different thermal expansion coefficients. This means that the two metal parts expand to the same extent when heated and thermal stresses are avoided.

It is also possible for both metal parts to be made from different materials and/or material combinations, in particular from two different metal materials. For example, a first metal part can be made from copper or a copper alloy and a second metal part from aluminum or an aluminum alloy. This means that aluminum cables, for example solid flat conductors, and copper conductors, for example flexible stranded conductors, can each be connected to a metal part of the cable connector in a single type. In this way, contact corrosion between the cable and the connector is reduced or prevented.

At least one of the metal parts can be made of solid material. This is advantageous for the heat capacity of the component. It is also possible for at least one of the metal parts to comprise segments of flat parts. In this way, high stability can be achieved with low weight and low material usage. On the other hand, the increased surface can promote heat radiation and thus enable a higher maximum loss of the cable connector. In any case, the size of the metal parts can be adapted to the cable thickness and/or current strength and thus to the expected heat generation and power loss. A larger size leads to a larger surface area over which heat can be radiated and transported away by convection. In addition, a larger volume leads to a higher heat capacity.

Connection terminals for conductors can be provided on one or both metal parts. These can be round, flat or otherwise shaped connection lugs. The connection lugs can be designed for soldering or welding cables, e.g. friction welding, ultrasonic welding, resistance welding, laser welding, etc. The connection lugs can be roughened, coated or otherwise surface-treated. One or more holes can also be provided in the connection lugs. The connection terminals can also be shaped as sleeves and/or cable lugs. They can be suitable for contacting and/or receiving flat conductors, round conductors, solid conductors and/or stranded wires. The connection terminals are preferably made of the same material as the metal part to which they are attached. They can also be made of a different material.

In order to define the relationships between surfaces, surface normals are used. A surface is a connected area on a three-dimensional body that can be divided into several segments. A surface does not have to be flat, but can be composed of segments with different spatial orientations. The orientation of a surface segment is characterized by its surface normal. A surface normal is a vector that is exactly perpendicular to the corresponding surface segment. In the following, surface normals of a surface segment of a body are directed away from the body so that the vector lies outside the body. The length of the surface normal vector is irrelevant and is defined as normalized to a value, for example the value 1 of a certain chosen unit of length. Two vectors are described below as being opposite to each other if their scalar product is less than zero. It is possible but not necessary that the two vectors are exactly antiparallel to each other. If the two vectors are perpendicular to each other, their scalar product is exactly zero.

The two metal parts rest against each other in certain areas. A locking element is provided that moves the two metal parts apart.

The locking element moves each metal part in a respective locking direction. The respective locking direction can be represented by a vector. The locking directions of both metal parts are opposite to each other (see above, scalar product less than zero) and can in particular be essentially antiparallel to each other.

The locking element is formed as a locking surface on each of the two metal parts, which are directed opposite one another and are spaced apart from one another by a gap. By introducing a third element, a locking part, between the two locking surfaces, the two metal parts are moved apart.

The locking part can be shaped as a cuboid, cylinder or otherwise, in particular the locking part can be tapered along a spatial axis. The locking part can thus be shaped as a wedge. The locking part is preferably inserted into the gap in an insertion direction that is different from the locking directions of both metal parts. The insertion direction can be aligned essentially perpendicular to the locking direction of at least one of the two metal parts. To ensure a better hold of the locking part, it can be roughened, for example by means of knobs, grooves, a corrugation, a rough coating, etc. At least one of the locking surfaces can also be correspondingly It is also possible for the locking element and/or at least one of the locking surfaces to be coated, for example with non-conductors such as silicone, rubber, plastic, which can deform elastically in particular and thus absorb mechanical stresses. The locking element and/or at least one of the locking surfaces can also be coated with a conductive coating such as nickel, tin, etc., which can be softer than the other material of the locking part.

The locking part can be made at least partially from a similar or the same material as one or both of the metal parts. This choice of material avoids different thermal expansion coefficients and prevents contact corrosion. It is also possible for the locking part to be made from a different material than at least one of the metal parts, which can be either conductive or non-conductive. The locking part can be made from a solid material. It can be made from a material that is not very compressible, such as solid copper or aluminum. It is also possible for the locking part to be made from an elastic material such as plastic, rubber, silicone, etc., or from material combinations such as rubberized glass or ceramic. A locking part made from a solid material can fit exactly into the gap between the two locking surfaces, at least in sections, the width of which is predetermined by the other design of the connector as described below.

It is also possible that the locking part is not formed from a solid material, but has an elastic structure with spring characteristics. For example, it can comprise metal brackets. The elastic elements, for example brackets, can absorb mechanical stresses as deformation and can be flexibly inserted into the gap between the locking surfaces. No further material has to be arranged between the elastic elements. However, it is also possible that the locking part comprises other components in addition to the elastic elements, such as a supporting, electrically conductive or non-conductive filling, which can be solid or elastic, etc.

The locking part can be formed as a separate element, completely separable from the two metal parts. It can also be attached in a guided manner to one of the two metal parts. For example, a rail can support the locking part so that it can move in essentially one direction. It is also possible to arrange the locking part so that it can rotate on one of the metal parts and screw it in to lock it. Since the contact with a screwed-in locking part can be small compared to a pushed-in locking part, it is particularly advisable to roughen the surface, for example by grooves. The advantage of a guided locking part is that it cannot be lost if the connection is opened again. It can also be advantageous during assembly if no separate locking parts have to be kept in stock.

The metal parts rest against one another in certain areas. Contact surfaces are initially provided for this purpose. Each of the two metal parts has a front contact surface which lies behind the locking element in the locking direction of the metal. Each of the two metal parts also has a second, rear contact surface which lies in front of the locking element in the locking direction. The locking element or the components of the locking element which are arranged on the respective metal part therefore lie between the two contact surfaces, the rear and the front, of the metal part. The rear contact surface is spaced from the locking element against the respective locking direction of the metal part, the front contact surface is spaced from the locking element with the respective locking direction of the metal part. In this case, locking element means the part of the locking element which is part of the respective metal part. For example, this can be the locking surface on the respective metal part described above.

In addition to the two contact surfaces, the front and the rear, each of the two metal parts also has two further surfaces, the impact surfaces. A first, front The abutment surface is spaced apart from the locking element in the locking direction of the respective metal part. A second, rear abutment surface is spaced apart from the locking element against the locking direction of the respective metal part. The front abutment surface of each metal part is thus on the same side of the locking element as the front contact surface along the locking direction. The rear contact surface and the rear abutment surface of the same metal part are arranged on the other side of the locking element. The front abutment surface can be further away from the locking element in the locking direction than the front contact surface in some areas. The front abutment surface can also be closer to the locking element than the front contact surface in some areas. The same applies to the rear contact and abutment surfaces.

The front (rear) contact surface and the front (rear) abutment surface of at least one metal part can merge directly into one another, so that an uninterrupted line can be drawn from the abutment surface into the contact surface. The front (rear) contact and abutment surfaces can also be separate from one another.

The two metal parts can be shaped essentially identically to each other.

A joined state of the two metal parts can now be defined. In this case, the front contact surface of the first metal part rests at least partially on the rear contact surface of the second metal part and the rear contact surface of the first metal part rests at least partially on the front contact surface of the second metal part. The front abutting surface of the first metal part also rests at least partially on the rear abutting surface of the second metal part and the rear abutting surface of the first metal part at least partially on the front abutting surface of the second metal part. In this case, abutting means that the surfaces can exert a force on one another directly or indirectly. Preferably, a mechanical and an electrical contact is established between the contact surfaces and/or between the end surfaces by the abutting. It can also another element can be arranged between the surfaces, for example a conductor or a non-conductor. In the case of the abutting surfaces, such an intermediate layer can, for example, absorb mechanical stress and/or facilitate the sliding of the metal parts against each other. In the case of the contact surfaces, such an intermediate layer can, for example, be a conductive, soft film that compensates for unevenness and creates good contact. The intermediate elements mentioned as examples can also be used on the other surfaces (abutting or contact surfaces).

In any case, a large-area contact of the surfaces, especially the contact surfaces of the two metal parts, is advantageous in order to achieve a low ohmic resistance and good thermal conductivity.

When joined, the two metal parts can have a substantially closed outer surface, which can, for example, essentially describe a cuboid, a cylinder, a sphere, an ellipsoid, a wedge or similar. The precise interlocking of the two metal parts avoids unnecessary edges, thus reducing the risk of damage to adjacent cables or other components, especially in tight cable harnesses.

The abutting surfaces of each metal part serve, in the joined state, the purpose of stopping the movement of the other metal part in its locking direction. When moving in its locking direction, the first metal part thus abuts with at least one of its two abutting surfaces, preferably both abutting surfaces, the rear and the front, against the abutting surfaces of the second metal part, the front and/or the rear. For this purpose, the abutting surfaces of each of the two metal parts are directed at least partially against the locking direction of the other metal part. Reference is made here to the above definition of "directed in the opposite direction", which states that the scalar product between the surface normals of the abutting surfaces of a metal part and the vector of the locking direction of the other metal part is negative. "At least partially" is to be understood as meaning that at least part of the surface has a corresponding orientation. Since the surface does not have to consist of a single flat segment, it is conceivable that some areas of the abutting surfaces are not directed in the opposite direction to the locking direction of the other metal part, but others are. In particular, the areas of the abutting surface should be directed in the opposite direction to the locking direction of the other metal part, where the other metal part actually rests in the joined and/or locked state.

For each pair of abutting surfaces, e.g. the rear of one metal part and the front of the other metal part, only one of the two abutting surfaces can be directed in the opposite direction to the direction of movement of the other metal part. The other abutting surface can also be shaped as a linear or point-shaped or other local elevation. Multiple elevations are also conceivable. The two abutting surfaces of a pair can also be flat and, when locked, essentially parallel to one another.

As a further, second purpose, the abutment surfaces redirect the force emanating from the locking element at least in part in the direction of the contact surface. To do this, the front contact surface and the front abutment surface of a metal part are first defined as "belonging" to the other surface, and the rear contact surface and rear abutment surface of one and the same metal part are defined as "belonging" to each other. The redirection of the force is now achieved by each abutment surface not only facing the locking direction in some areas, but also areas of the respective associated contact surface. Consequently, the contact surface of the associated abutment surface is also facing the opposite direction in some areas.

The locking element therefore exerts a force on the contact surfaces via the abutting surfaces and presses them against each other with a normal force. The front contact surface of the first metal part is therefore pressed against the rear contact surface of the second metal part. The rear contact surface of the first metal part is also pressed against the front contact surface of the second metal part. pressed. A large force is advantageous in order to ensure good contact with low contact resistance. As described above, it is advantageous if both metal parts and the locking part have similar or equal expansion coefficients so that the normal force does not decrease due to different expansion coefficients in an expected temperature range of -40°C to 150-180°C.

As described above, the surfaces, i.e. both contact surfaces and abutment surfaces, do not have to be completely flat and formed from a single flat segment, but can be formed from several differently aligned segments. In particular, the contact and/or abutment surfaces can be provided with a relief. This can be shaped as ribs and grooves along which one metal part can slide along the other. For example, these relief structures can be essentially constant along the respective locking direction, in particular if the locking direction of a metal part runs exactly perpendicular to the surface normal of a relief contact surface. It is also possible for the contact and/or abutment surfaces to be concave and/or convex. In an advantageous embodiment, the relief structures of the two metal parts engage with one another, so that on the one hand the size of the contact surface is increased compared to flat surfaces and on the other hand the metal parts are guided against one another. In particular, for example, the front contact surface in each case can have concave recesses and the rear contact surface in each case can engage with a convex shape in these concave recesses. The front contact surface can also have convex recesses and the rear contact surface can engage in these convex recesses with a concave shape. The same can apply to front and rear impact surfaces. Of course, other surface structures are conceivable, such as jagged, triangular, toothed reliefs, etc.

In a preferred embodiment, the contact surfaces of a first metal part are at least partially parallel to the locking direction of the respective metal part and/or the other metal part. The same can apply to the second metal part. The metal parts can then slide along each other at the contact surfaces.

The contact surfaces of a metal part, front and rear, can also be aligned parallel to one another, at least in some areas, but also entirely. The two contact surfaces of both metal parts can also be aligned parallel to one another, at least in some areas, or entirely. The same can apply to the abutting surfaces, both for one metal part and for both metal parts equally.

The contact surfaces of a pair of contact surfaces that are adjacent to one another, formed from one contact surface of each of the two metal parts, can also be essentially parallel to one another. This can apply to both pairs of contact surfaces of the cable connector. The same can apply to the abutting surfaces.

In a preferred embodiment, both the locking directions of both metal parts and the surface normals of both contact surfaces and both abutting surfaces of both metal parts each run, at least in some areas, essentially parallel to a common plane or to each other.

The abutting surfaces and/or contact surfaces can be coated at least in some areas. In particular, they can be provided with a nickel and/or tin coating, which can be softer than the main material of the metal parts and thus creates better contact. The abutting surfaces and/or contact surfaces can also be surface-treated in another way, for example polished and made particularly smooth.

As an alternative to the locking element consisting of locking surfaces and a retractable locking part, other designs are conceivable. For example, a screw mechanism is conceivable that is anchored in a thread in one of the two metal parts and can be brought closer to a locking surface against the other metal part. Both metal parts can also have screw elements that can be extended towards each other. Snap elements or spring elements that are firmly attached to the metal part are conceivable, which are tensioned when the two metal parts hook into each other, thus exerting a permanent force and keeping the metal parts in contact with each other when joined.

To protect against moisture and other environmental influences, a protective sheath can be provided for the cable connector. This can include a coating on the metal parts, for example made of plastic, silicone, ceramic, rubber, glass, etc. This coating is preferably applied to the surfaces of the metal parts that are not contact and/or abutment surfaces. The coating can also be arranged in the area of the locking element, but the surface of the metal parts in this area can also be excluded from it. In order to achieve a good seal of the cable connector when joined, the coating can protrude laterally beyond the contact and abutment surfaces so that when joined, no gap remains through which water and other chemicals can penetrate. The protruding coating edges can also be arranged as a groove on one metal part and a lip on the other metal part so that they engage when the metal parts are joined. The edges of the coatings of both metal parts can also have the same shape, such as lips, thickenings, grooves, etc. It can be advantageous to choose a coating of one metal part that is harder than the coating of the other metal part, so that the coating edge of the first metal part can press into the coating of the other metal part and thus achieve a better sealing effect.

It can happen that the locking element leaves an opening in the cable connector, for example if a locking part is recessed between the locking surfaces. In order to achieve insulation against moisture and other environmental influences, a cover can be provided that covers the remaining opening. The locking part itself can also close the opening created by the two metal elements. For this purpose, the wedge can for example, have an insulating cap. A closure of the opening can in particular provide protection against contact, in particular against fingers (standard IPxxB) or wires (standard IPxxD), and/or seal the opening in a watertight and/or airtight and/or hermetically sealed manner.

It is also possible to have a housing around the entire cable connector, which is placed around it when it is assembled. The housing can be made of silicone, rubber, preferably of harder materials such as plastic, or even ceramic. Two or more housing parts can also be placed separately around both metal parts and/or attached to them and these can also be fitted together to form a seal when assembled. Snap elements and/or a circumferential seal made of a softer material than the housing, for example silicone or rubber, can ensure a permanent sealing effect.

In a further embodiment, a metal part can have two further contact surfaces, two further abutment surfaces and parts of a further locking element in addition to the first two contact surfaces, abutment surfaces and parts of a first locking element. The metal part designed in this way can be connected to one, two or more further metal parts and thus enable a Y-connection, for example. A metal part can also have further connection surfaces and locking elements and enable a 4-way, 5-way and 6-way coupling or a connection of more elements and/or cables.

The metal parts can be manufactured in particular by, for example, die casting, precision casting or an extrusion process. These processes enable a particularly fine, flat and uniform surface. However, it is also possible to choose other processes, which can be combined with a subsequent surface treatment if necessary.

Fig. 1

Ausführungsbeispiel der beiden Metallteile des gegenständlichen Kabelverbinders;

Fig. 2

Ausführungsbeispiele eines gegenständlichen Metallteils mit eingezeichneten Flächennormalen;

Fig. 3

Ausführungsbeispiele von zwei ineinander gehakten gegenständlichen Metallteilen in der Draufsicht;

Fig. 4

Ausführungsbeispiele des gegenständlichen Kabelverbinders in isometrischer Ansicht;

Fig. 5

Ausführungsbeispiele der Stoßflächen des gegenständlichen Kabelverbinders;

Fig. 6

Ausführungsbeispiele des Verriegelungselements des gegenständlichen Kabelverbinders;

Fig. 7

Ausführungsbeispiele der Konturen von Stoß- und Kontaktflächen des gegenständlichen Kabelverbinders;

Fig. 8

Ausführungsbeispiel eines isolierten gegenständlichen Kabelverbinders;

Fig. 9

Ausführungsbeispiel eines gegenständlichen Kabelverbinders mit einem für mehrere Kontaktierungen vorgesehenen Metallteil;

Fig. 10

Ausführungsbeispiele von Anschlussterminals des gegenständlichen Kabelverbinders.

The subject matter is explained in more detail below using a drawing showing exemplary embodiments. The drawing shows:

Fig.1

Example of the two metal parts of the cable connector in question;

Fig.2

Examples of an actual metal part with surface normals drawn in;

Fig.3

Embodiments of two interlocking metal parts in plan view;

Fig.4

Embodiments of the cable connector in question in isometric view;

Fig.5

Examples of the abutting surfaces of the cable connector in question;

Fig.6

Embodiments of the locking element of the cable connector in question;

Fig.7

Examples of the contours of abutment and contact surfaces of the cable connector in question;

Fig.8

Embodiment of an insulated cable connector;

Fig.9

Embodiment of a cable connector in question with a metal part intended for multiple contacts;

Fig.10

Examples of connection terminals of the cable connector in question.

The cable connector 1 in question is formed from a first metal part 20 and a second metal part 40. These are in Fig. 1a The first metal part 20 has a front abutment surface 28, a rear abutment surface 22, a front contact surface 26 and a rear contact surface 24. A second metal part 40 is provided in a similar manner. This in turn has a front abutment surface 48, a rear abutment surface 42, a front contact surface 46 and a rear contact surface 44.

It may be advantageous to match the two metal parts 20, 40 in their external dimensions, in particular their thickness, so that few edges protrude after joining. In particular, it is possible for the two metal parts to be shaped essentially identically.

Fig. 1b shows the two metal parts 20, 40 in the joined state. Here, the front abutting surface 28 of the first metal part 20 rests on the rear abutting surface 42 of the second metal part 40 and the rear abutting surface 22 of the first metal part 20 rests on the front abutting surface 48 of the second metal part 40. The rear contact surface 24 of the first metal part 20 also rests on the front contact surface 46 of the second metal part 40 and the front contact surface 26 of the first metal part 20 rests on the rear contact surface 44 of the second metal part 40. This essentially results in a cuboid.

The fact that the surfaces are in contact with one another can be understood to mean that they exert a force on one another, at least in some areas. They can also be in contact with one another indirectly via one or more other elements arranged between the contacting surfaces.

The two metal parts 20, 40 are pushed against each other via a locking element 60. In the embodiment shown, a wedge is used as the locking part 66, which is pushed between two locking surfaces 62, 64. A first locking surface 62 is located on the first metal part 20 and a second locking surface 64 on the second metal part 40. By pushing in the locking part 66, it comes into contact with both locking surfaces 62 and 64 and pushes them, and thus the metal parts 20, 40, apart. The locking part 66 can preferably fit precisely into the gap inserted so that it is a press fit between the locking surfaces 62, 64. The locking part 66 can be pressed into the gap between the locking surfaces 62, 64 with a predetermined pressure or force.

An end position can be defined for the locking part 66, in which the two metal parts 20, 40 are firmly locked together and the locking part 66 can only be moved with the application of force due to friction on the locking surfaces 62, 64. In this state, the locking part 66 can protrude beyond the surface of the metal parts 40, 60, be flush with at least one of them, or form a recess in the cable connector 1.

The first metal part 20 is moved by the locking element 60 in a first locking direction 50, the second metal part 40 is moved in a second locking direction 52. The locking directions 50, 52 are different from one another, in particular opposite to one another (scalar product <0) and can in particular be antiparallel to one another.

Referring to Fig.2 It should be explained that the evaluation of whether two vectors are perpendicular to each other can be carried out in such a way that the vectors are shifted so that their starting points are identical (see right part Fig.2 ). For the case shown in Fig.2 It becomes obvious that the surface normal vectors 23, 29 of the abutting surfaces 22 and 28 of the first connection part 20 are opposite to both the locking direction 52 of the second metal part 40 and the surface normal vectors 25, 27 of the contact surfaces 24 and 26.

On the one hand, this ensures that the first metal part 20 stops the second metal part 40 in the locking direction, since the abutting surfaces 42 and 48 of the second metal part 40 rest against the abutting surfaces 22, 28 of the first metal part 20, which are directed opposite to the locking direction 52 of the second metal part 40. This applies in exactly the opposite way to the first metal part 20, which is held by the abutting surfaces 42, 48 the second metal part 40 is prevented from moving further in its locking direction 50.

In addition, the alignment of the abutment surface normals 23, 29 against the associated contact surface normals 25, 27 causes the second metal part 40, which is moved by the locking element 60 against the abutment surfaces 22, 28, to be redirected in the direction of the contact surface 24, 26. The second metal part 40 now abuts these contact surfaces 24, 26 with its respective contact surfaces 46, 44, so that it is held at least in a force-fitting and form-fitting manner.

Fig.3 shows various possible alignments of the contact surfaces 24, 46, 26, 44 and abutting surfaces 28, 42, 22, 48 of the two metal parts 20, 40. A top view of the cable connector 1 in question is shown. The contact and abutting surfaces 24, 46, 26, 44 can essentially run as flat surfaces with a single alignment perpendicular to the plane of the drawing. They can also be curved, twisted or otherwise deformed. For the following considerations, at least one segment of each surface should be aligned essentially perpendicular to the plane of the drawing, so that the seam lines of the Fig.3 the area-wise alignment of the surfaces can be seen. The locking directions 50, 52 of the two metal parts 20, 40 are shown in the Fig. 3 a.c. shown embodiments parallel to the contact surfaces 24, 26, 44, 46, which are aligned parallel to each other in the joined state.

For a more detailed explanation of the surface orientations, see Fig.3 , in which the surface normals 23 (vertical to rear abutment surface 22), 25 (vertical to rear contact surface 24), 27 (vertical to front contact surface 26), 29 (vertical to front abutment surface 28) for the first metal part 20 are shown.

It can be seen that in all embodiments of the Fig. 3 a.c. the abutting surfaces 22, 28, 42, 48 are directed opposite to the locking direction of the other metal part (scalar product between surface normal vectors 23, 25, 27, 29 and locking direction vector 50, 52 < 0).

It can also be seen that the surface normal vectors 23, 29 of the abutting surfaces 22, 28 are directed opposite to their respective corresponding contact surface.

In Fig. 3d a design is shown in which the contact surfaces 24, 26, 44, 46 are curved in plan view. They can also be curved so much that their area-specific surface normals are no longer directed opposite to the surface normals of the associated abutting surfaces 22, 28, 42, 48. It is sufficient if the surface normals of the contact surfaces 24, 26, 44, 46 are directed opposite to the surface normals of the associated abutting surfaces 22, 28, 42, 48 in some areas.

In the examples from Fig. 3 ad the abutting surfaces 22, 28, 42, 48 are generally further away from the locking element 60 than the respective associated contact surfaces 24, 26, 44, 46. The abutting surfaces 22, 28, 42, 48 can also, as in Fig. 3 e shown, closer to the locking element 60 than at least areas of the associated contact surfaces 24, 26, 44, 46.

Contact and abutment surfaces 24, 26, 44, 46, 22, 28, 42, 48 generally do not have to be formed from a single flat segment but can also comprise segments of different orientations. An example design with such surfaces is shown in Fig. 3 f shown. Here, the abutting surfaces 22, 48, 26 and 42 were first separated into sub-areas (22a, 22b, 22c, as well as 48a, 48b, 48c and 28a, 28b, 42a, 42b), each of which has an orientation according to the invention. The horizontal abutting surface areas in the figure have a different orientation. Overall, the abutting surfaces comprise these horizontal sub-areas and the sub-areas aligned according to the invention (22a, 22b, 22c, as well as 48a, 48b, 48c and 28a, 28b, 42a, 42b). The abutting surface 28 was provided with highlights. The elevations 28a, 28b themselves can also be regarded as the abutting surface 28. Their surface orientation is irrelevant for the function of the invention. However, at least small segments of the result will be aligned against both the locking direction 52 of the second metal part 40 and the surface normal of the associated contact surface 26. The alignment of the abutment surface 42, more precisely its partial areas 42a, 42b, already causes the first metal part 20 is pressed with its contact surface 26 against the contact surface 44 of the second metal part 40. It is clear here that the regionally objective alignment of the two contacting abutting surfaces (22, 48) and (28, 42) is sufficient to press the associated contact surfaces (24, 46) and (26, 44) against each other by means of the locking element 60.

Fig. 3 g shows another related embodiment in which the abutting surfaces 22, 48 and 28, 42 are divided into three sub-areas, each with a substantially constant alignment. The horizontally aligned sub-areas (surface normal substantially vertical) are aligned according to the invention. The vertically aligned sub-areas (surface normal substantially horizontal) alone would not achieve the desired locking. Here too, the abutting surface can refer to either just the horizontally aligned sub-area or the combined surface made up of two vertical and one horizontally aligned sub-area.

Fig.4 shows two different exemplary designs of the metal parts 20, 40. In the Fig. 4a Both metal parts 20, 40 are formed from several flat segments. The contact surfaces 24, 26, 44, 46 and abutment surfaces 22, 28, 42, 48 are each formed from flat segments that are essentially parallel to the respective contact or abutment surface. To increase mechanical stability, vertical flat elements are provided. These are optional. One advantage of this design is the lower material expenditure, another is the increased surface area to the environment, through which heat can be radiated and released in other ways, such as via convection.

Another design, shown in the Fig. 4b , resembles a cylinder. A cylindrical shape makes it easier to integrate the cable connector 1 into cable harnesses. This is because the connector can be made to approximately match the cable diameter, particularly for cables with a round diameter. In this way, thickenings along the cable harness in the area of the Cable connector 1 is avoided. Thanks to the lack of edges, damage to neighboring components, especially cables, is also less likely.

Fig.5 carries out the embodiment Fig. 3g even further. One of the abutting surfaces of two abutting surfaces in contact with each other can be shaped as one or more point-like, linear or otherwise shaped elevations instead of as a surface. The elevation can be flattened and have a front surface that is aligned essentially parallel to the surface against it when locked. It can also be rounded. A rounded design is in Fig. 5a shown. If the elevation is rounded, only a very small surface segment of the abutment surface 42 is aligned against the locking direction 50 of the first metal part 20 and the surface normal of the contact surface 44. The alignment of the other abutment surface, which is formed as a surface, is sufficient to guide the two contact surfaces associated with the respective abutment surfaces towards each other based on the force emanating from the locking element 60. The elevations of one abutment surface can, for example, essentially form a line as in Fig. 5b Here the survey is not, as in Fig. 5a , rounded, but has a flattened front surface. A rounded shape is just as possible. Several such linear elevations parallel to each other or inclined to each other are also possible. Alternatively, point elevations as in Fig. 5c conceivable. Here too, individual or multiple elevations distributed in an orderly or random manner on the abutting surface are conceivable. Alternatively, at least one abutting surface can be heavily roughened, resulting in an irregularly shaped surface structure with elevations and depressions which, when the cable connector 1 in question is locked, partially come into contact with the opposite abutting surface of the other metal part and/or are pressed in and/or penetrate into the opposite abutting surface.

Fig.6 shows possible embodiments of locking elements 60, in addition to the Fig. 1a disclosed wedge 66 with locking surfaces 62, 64.

In particular, some guided designs of locking parts 66 are disclosed. The guide 67 can have the property that the locking part 66 can only move in one direction. Furthermore, the guide 67 can connect the locking part 66 to at least one of the metal parts 20, 40 in a captive manner. This has the advantage that for the assembly of the cable connector 1 in question only two separate elements have to be handled, namely the two metal parts 20, 40. No locking part 66 has to be kept in stock in a processing machine, etc. Even if the cable connector 1 is opened, the locking part 66 is not in danger of being lost.

In Fig. 6a a wedge is disclosed as a locking part 66 which is movable along a guide 67. This guide 67 can comprise a rail or other substantially linear elevation in the locking surface 62 which is surrounded by a groove or other substantially linear recess in the locking part 66. Also, the guide can be arranged as a recess in the locking surface 62 of the metal part 20 (or the locking surface 64 of the metal part 40) and the elevation on the locking part 66.

Another example of a locking element 60 with guide 67 is shown in Fig. 6b shown. Here, the locking part 66 can be rotated around a guide 67 formed as a rotary bearing. By turning the locking part 66 from the upper to the lower position shown of the Fig. 6b the locking of the cable connector 1 is achieved. A rounding of the locking part 66 shown is advantageous in order to completely insert the locking part 66 in the gap into the lower part of Fig. 6b to be able to move to the end position shown.

In both shown, but also in other locking element configurations, it can be helpful to increase the friction between the locking part 66 and the locking surfaces 62, 64. This can be done by roughening the surface, by sandblasting, etching, and other processes or by means of a targeted relief, for example during casting, by means of which grooves, Knobs, waves, etc., which can increase the friction between locking part 66 and locking surfaces 62, 64. Fig. 6c shows examples of roughened surfaces.

Alternative locking elements 60 are in Fig. 6 df shown. In Fig. 6d the locking element 60 comprises a screw guided in a thread of a first metal part 20, which can be rotated against the locking surface 64 of the second metal part 40. The locking part 66 is the screw in this case.

Fig. 6e shows a spring element as a locking part 66, which is fixedly or movably attached to the locking surface 62 of the first metal part 20 and is pressed in when the two metal parts 20, 40 are put together, so that the restoring force of the spring element moves the two metal parts 20, 40 apart. Analogous to the Fig. 6e shows Fig. 6f another spring element. The spring element of the Fig. 6d has the advantage that a lateral insertion does not deflect the spring downwards significantly and that it can press the metal part in the locking direction even after insertion. The spring of the Fig. 6f may require further guidance in the spring direction. Spring elements as locking parts 66 generally have the advantage that the two metal parts 20, 40 can be put together and locked immediately. The disadvantage, however, is a significantly reduced force emanating from the locking element 60 compared to, for example, a metal wedge fitted under pressure in a press fit. This reduces the normal force on impact and contact surfaces and the contact can have a higher resistance.

As already discussed, contact surfaces 24, 26, 44, 46 and abutment surfaces 22, 28, 42, 48, and also the locking surfaces 62, 64 need not be flat with a single orientation but may also have regions of different orientations. Some examples of such surface shapes are shown in Fig.7 shown. Here, a relief is shown, as would be made visible by a section through the two metal parts 20, 40. It is advantageous if the surfaces of the metal parts 20, 40 can slide along each other in a preferred direction. This can be used for the contact surfaces be ensured by the profile being constant over a direction perpendicular to the locking direction of the metal part along the locking direction of at least one of the metal parts. For example, grooves can be seen in the metal along this direction. For the abutting surfaces 22, 28, 42, 48, a constant relief in the direction of the associated contact surface is helpful so that the metal part slides along this profile towards the contact surface. Fig. 7a shows a described advantageous profile curve with an exemplary angular profile.

It is also helpful if the metal parts 20, 40 interlock at the contact and abutment surfaces. In this way, the metal parts 20, 40 are guided securely. In addition, they hold together better when locked and the contact surface is larger compared to flat contact and abutment surfaces. The profiling described is particularly advantageous for the contact surfaces.

Fig. 7b shows a first wave-shaped profile, in Fig. 7c a concave profile of a first surface and a complementary convex profile of a second surface are shown. In Fig. 7d another embodiment of interlocking surfaces is shown.

In order to improve the contact between the contact and abutment surfaces, these can be coated, in particular with softer metals such as nickel or tin. Other metals such as gold or other conductive materials are also conceivable. A coating is advantageously only applied in the area of the contacting contact and abutment surfaces, see coatings 70,72 in Fig. 6e .

The cable connector 1 described so far generally still has an unprotected metal outer surface. This has the disadvantage that it can come into electrical and mechanical contact with other conductors, and there is also the risk of corrosion or other damage due to environmental influences. In order to eliminate these risks, it is advantageous to have the cable connector 1 facing outwards. This can be done by means of a housing which is placed around the cable connector 1 after connection and locking.

Fig. 8a shows another advantageous embodiment of insulation from the environment. Here, the metal parts 20, 40 are coated with an insulation layer 80 on at least parts of the outer surfaces that are not contact surfaces, abutting surfaces, locking surfaces or other outer surfaces that are not to be insulated. This is preferably a non-conductor and can be made of plastic, silicone, rubber, but also of ceramic, glass, etc.

In order to enable complete insulation of the metal parts 20, 40 of the cable connector 1 in the locked state, a cover 82 can close the opening in the area of the locking element 60 after locking. The cover 82 can also be part of the locking part 66, which has an insulating closure, for example, which blocks the opening when inserted. The cover can also be formed as part of the housing. It is also possible for the head of the wedge to be coated with insulation. The wedge can also be formed as part of the housing.

In the area of the transitions between the insulation layer 80 and contact and/or abutment surfaces, which must be in direct electrical and mechanical contact with each other, there is an increased risk of moisture penetrating. To avoid this, the insulation layer 80 can protrude over the surfaces as in Fig. 8 c, d shown. A groove 84 in the projection of the insulation layer 80 on one metal part and a corresponding projection 86 engaging in the groove on the insulation layer 80 of the other metal part can enable increased insulation performance in the transition between the two metal parts 20, 40. Several grooves 84 and lips 86 can also be provided, which are arranged next to one another and each engage with one another, thus increasing the sealing effect.

Also, as in Fig. 8d shown, an insulation layer 80 a,b of a first metal part 20 may be softer than the insulation layer 80 c,d of the second metal part 40. As a result, Because the projection of the harder insulation layer 80 c,d can press into the softer insulation layer 80 a,b, the insulation becomes particularly dense.

The cable connectors 1 described so far are intended for connecting two cables or other components. It is also possible to extend the connection concept to several cables. In Fig.9 a cable connector 1 is shown in which the second metal part 40 has several docking points for cable connectors 1, each comprising a front abutment surface 48, front contact surface 46, rear contact surface 44 and rear abutment surface 42. At least parts of locking elements 60 are also provided. Fig. 9a demonstrates a star-shaped design, Fig. 9b a juxtaposed design.

To connect the cable connector 1 to the cable, connections are required. Fig.10 some examples of cable connection terminals 90. In Fig. 10a A tab with a hole is shown for this purpose. This can be used for screw or rivet connections. Fig. 10b shows a flat terminal 90 without a hole, for example for press or solder connections. Fig. 10c shows a round terminal 90. This can be formed as a solid material. For example, cables can be welded to it, in particular by means of friction welding, ultrasonic welding, and/or laser welding. A hollow design as a sleeve 90 as in Fig. 10d shown, which can accommodate cables or other elements, for example as a cable lug. The sleeve 90 can also have a round cross-section.

Claims (15)

1. Cable connector (1) for motor vehicles comprising

   - a first metal part (20),

   - a second metal part (40) abutting the first metal part (20),

   - a interlocking member (60) moving the two metal parts (20, 40) in a respective locking direction (50, 52),

   - wherein each of the two metal parts (20,40) has a respective front abutment surface (28, 48) and associated front contact surface (26, 46) remote from the interlocking member (60) in the locking direction (50, 52) of the respective metal part (20, 40) and a respective rear abutment surface (22, 42) and associated rear contact surface (24, 44) remote from the interlocking member (60) opposite to the locking direction (50, 52) of the respective metal part (20, 40),

   - wherein, in a locked state of the cable connector (1), the front abutment surface (22, 42) of each of the two metal parts (20, 40) abuts the rear abutment surface (22, 42) of the respective other metal part (20, 40), and the front contact surface (24, 44) of each of the two metal parts (20, 40) abuts the rear contact surface (24, 44) of the respective other metal part (20, 40), wherein

   - the surface normals of the front and rear abutment surfaces (22, 24, 42, 44) of a respective one of the metal parts (20, 40) run at least in regions opposite to the locking direction (50, 52) of the respective other metal part (20, 40), and

   - for each of the two metal parts (20, 40), the surface normals of the front abutment surfaces (22, 42) run at least in regions opposite to the surface normal of at least part of the associated front contact surfaces (24, 44), and

   - for each of the two metal parts (20, 40), the surface normals of the rear abutting surfaces (22, 42) run at least in regions opposite to the surface normal of at least a part of the associated rear contact surfaces (24, 44),
   characterized in that

   - the interlocking member (60) moves the two metal parts (20, 40) apart from each other in their respective locking direction (50, 52)

   - the interlocking member (60) comprises a first locking surface (62) on the first metal part (20) and a second locking surface (64) on the second metal part (40), which are opposite to each other, and which are spaced apart by a gap, and

   - further comprising a locking member (66), which is inserted between the two locking surfaces (62, 64) and moves them apart.
2. Cable connector (1) for motor vehicles according to one of the preceding claims,
   characterized in that

   - front contact surface of at least one of the two metal parts (20, 40) is substantially in direct contact with the rear contact surface (24, 44) of the respective other metal part (20,40) over the width perpendicular to the locking direction (50, 52), at least in regions, and the surface profiles of the two contact surfaces are substantially constant along the locking direction (50, 52) of at least one of the two metal parts (20, 40).
3. Cable connector (1) for motor vehicles according to any one of the preceding claims,
   characterized in that

   - the locking part (66) is formed as a locking wedge that abuts both locking surfaces (62, 64), so that the locking wedge pushes the two metal parts (20, 40) apart in their respective locking direction (50, 52).
4. Cable connector (1) for motor vehicles according to any one of the preceding claims,
   characterized in that
   the two metal parts (20, 40) are shaped substantially identically to each other.
5. Cable connector (1) for motor vehicles according to claim 1,
   characterized in that

   - the area-wise surface normals of front and rear abutting surfaces (22, 28, 42, 48) and front and rear contact surfaces (24, 26, 44, 46) of both metal parts (20, 40) and the locking directions (50, 52) of both metal parts (20, 40) are substantially parallel to a common plane.
6. Cable connector (1) for motor vehicles according to claim 1 or 2,
   characterized in that

   - the surface normals of the front and/or rear contact surfaces (24, 26, 44, 46) of at least one of the two metal parts (20, 40) are directed substantially in the same direction, at least in regions.
7. Cable connector (1) for motor vehicles according to any one of the preceding claims,
   characterized in that

   - the surface normals of the front and rear contact surfaces (22, 28, 42, 48) of at least one of the two metal parts (20, 40) are directed substantially in the same direction, at least in some areas.
8. Cable connector (1) for motor vehicles according to any one of the preceding claims,
   characterized in that

   - the locking direction (50) of the first metal part (20) is substantially opposite to the locking direction (52) of the second metal part (40), in particular that the locking directions (50, 52) of the two metal parts (20, 40) are antiparallel to each other.
9. Cable connector (1) for motor vehicles according to any one of the preceding claims,
   characterized in that

   - the front abutment surface (28, 48) of at least one of the two metal parts (20, 40) is at least partially concave in shape and/or the rear abutment surface (22, 42) of the respective other metal part (20, 40) is at least partially convex in shape, or the front abutment surface (28, 48) of at least one of the two metal parts (20, 40) is at least partially convex in shape and/or the rear abutment surface (22, 42) of the respective other metal part (20, 40) is at least partially concave in shape.
10. Cable connector (1) for motor vehicles according to any one of the preceding claims,
    characterized in that

    - the front abutment surface (28, 48) of one of the two metal parts (20, 40) has local, in particular punctiform or linear, elevations (28a, 28b).
11. Cable connector (1) for motor vehicles according to any one of the preceding claims,
    characterized in that

    - the front contact surface (26, 46) of at least a first one of the two metal parts (20, 40) is at least partially concave-shaped and the rear contact surface (24, 44) of the respective other metal part (20, 40) is at least partially convex-shaped, or in that the front contact surface (26, 46) of at least a first one of the two metal parts (20, 40) is at least partially convex-shaped and the rear contact surface (24, 44) of the respective other metal part (20, 40) is at least partially concave-shaped.
12. Cable connector (1) for motor vehicles according to any one of the preceding claims,
    characterized in that

    - at least one of the contact surfaces (24, 26, 44, 46) or abutting surfaces (22, 28, 42, 48) of at least one metal part (20, 40) has an electrically conductive coating, in particular a nickel, silver, gold or copper coating.
13. Cable connector (1) for motor vehicles according to any one of the preceding claims,
    characterized in that

    - at least one abutment surface (22, 28, 42, 48) of at least one metal part (20, 40) abuts indirectly against the abutment surface (22, 28, 42, 48) of the other metal part (20, 40) and a conductor or a non-conductor is arranged between the abutment surfaces (22, 28, 42, 48) and/or at least one contact surface (24, 26, 44, 46) of at least one metal part (20, 40) abuts indirectly against a contact surface (24, 26, 44, 46) of the other metal part (20, 40) and a conductor is arranged between the contact surfaces (24, 26, 44, 46).
14. Cable connector (1) for motor vehicles according to any one of the preceding claims,
    characterized in that

    - at least the first metal part (20) has at least two further contact surfaces (24, 26) and two further abutting surfaces (22, 28) in which a further metal part(40) can engage, and an at least second interlocking member (60) locks the first metal part (20) to the second metal part (40).
15. Method of manufacturing a cable connector (1) for motor vehicles comprising

    a first metal part (20),

    a second metal part (40) abutting the first metal part (20),

    a interlocking member (60) moving the two metal parts (20, 40) in a respective interlocking direction (50, 52), wherein each of the two metal parts (20, 40) has a front abutment surface (28, 48) located in the locking direction (50, 52) of the respective metal part (20, 40) remote from the interlocking member (60) and an associated front contact surface (26, 46) and has a rear abutment surface (22, 42) located opposite to the locking direction (60) of the respective metal part (20, 40) remote from the interlocking member (60) and an associated rear contact surface (24, 44),

    - wherein, in a locked state of the cable connector (1), the front abutment surface (28, 48) of each of the two metal parts (20, 40) bears against the rear abutment surface (22, 42) of the respective other metal part (20, 40) and the front contact surface (26, 46) of each of the two metal parts (20, 40) bears against the rear contact surface (24, 44) of the respective other metal part (20, 40), wherein

    the surface normals of the front and rear abutment surfaces (22, 28, 42, 48) of each respective one of the metal parts (20, 40) extend at least in regions opposite to the locking direction (60) of each respective other metal part (20, 40), and for each of the two metal parts (20, 40), the surface normals of the front abutment surfaces (28, 48) run at least partially in the opposite direction to the surface normal of at least a part of the associated front contact surfaces (26, 46), and

    for each of the two metal parts (20, 40), the surface normals of the rear abutment surfaces (22, 42) run at least partially in the opposite direction to the surface normal of at least a part of the associated rear contact surface (24, 44),

    in which

    at least one of the two metal parts (20, 40) and/or the interlocking member (66) are produced by die casting, investment casting and/or an extrusion process,

    characterized in that

    - the interlocking member (60) moves the two metal parts (20, 40) apart in the respective interlocking direction (50, 52), wherein

    - the interlocking member (60) comprises a first locking surface (62) on the first metal part (20) and a second locking surface (64) on the second metal part (40),

    which are directed towards each other, and which are spaced apart by a gap, and

    - further comprising a locking member (66) interposed between the two locking surfaces (62, 64) and moving them apart.

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