Patent Application
20220263271
This application claims the benefit of India Patent Application No. 202141006230 filed on Feb. 15, 2021, the whole disclosure of which is incorporated herein by reference.
The present invention relates to an electrical connector and, more particularly, to an electrical connector with a cover structure e.g., for high-voltage and high-amperage applications. Further
Electrical connectors are provided for establishing electrical connections, which serve the purpose of transferring electrical energy and/or signals. In the case of energy transfer in particular, a safety risk arises, which needs to be addressed accordingly. For example, before establishing said electrical connections, unintended contact of human fingers and tools with current carrying components of the electrical connectors (e.g., contact elements) needs to be prevented. Simultaneously, the contact elements need to maintain a certain accessibility, since the functionality of electrical connectors mostly relies on mating contacts of mating connectors engaging in electrical contact with the contact elements.
Existing solutions employ finger protection for the contact elements. This finger protection, however, often leaves small gaps for the mating contacts through which particularly small fingers and thin tools can unintendedly reach the contact elements. Gapless finger protection on the other hand often requires additional steps of attachment and/or removal. This renders the mating process cumbersome. Lastly, finger protection, which does not require such additional steps during the mating process often employs delicate cover elements, which exhibit low insulation capability, and is thus not suited for applications with high voltages and high currents.
According to an embodiment of the present disclosure, an electrical connector comprises at least one contact element, and a cover structure restricting access to the at least one contact element. The cover structure includes a wall element at least partially surrounding the at least one contact element and defines a reception zone between the wall element and the at least one contact element. The wall element includes at least one deflectable latch member. A cover element is movable within the reception zone along a retraction direction from a secured position to a retracted position. The at least one contact element is enclosed by the cover element in the secured position. The at least one deflectable latch member secures the cover element in the secured position.
The invention will now be described by way of example with reference to the accompanying Figures, of which:
Exemplary embodiments of the present disclosure will be described hereinafter in detail with reference to the attached drawings, wherein the like reference numerals refer to the like elements. The present disclosure may, however, be embodied in many different forms and should not be construed as being limited to the embodiment set forth herein; rather, these embodiments are provided so that the present disclosure will be thorough and complete, and will fully convey the concept of the disclosure to those skilled in the art.
In the following detailed description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the disclosed embodiments. It will be apparent, however, that one or more embodiments may be practiced without these specific details. In other instances, well-known structures and devices are schematically shown in order to simplify the drawing.
In the following, the structure of an exemplary embodiment of an electrical connector 1 according to the present invention is explained with reference to
The electrical connector 1 may comprise at least one electrically conductive contact element 16 (see
In the shown exemplary embodiment, the electrical connector 1 comprises two contact elements 16. In particular, the electrical connector 1 comprises two contact elements 16 extending along the mating direction 14 and parallel to each other. The number and/or orientation of contact elements 16, however, may be adapted according to the application of the electrical connector 1.
As shown, the electrical connector 1 further comprises an insulative cover structure 20 for restricting access to the contact elements 16. The cover structure 20 may be embodied by the connector housing 6 or be separately assembled to the connector housing 6. Alternatively, parts of the cover structure 20 may be monolithically connected to the connector housing 6. Other parts may be assembled to the connector housing 6 as separate components.
The cover structure 20 comprises a static wall element 22. The wall element 22, for example, may be monolithically connected to the connector housing 6. In the illustrated exemplary embodiment, the cover structure 20 comprises one wall element 22 for each contact element 16. Each wall element 22 at least partly surrounds the corresponding contact element 16 in a spaced apart manner. In particular, each wall element 22 comprises multiple wall sections 24, which extend parallel to and spaced apart from the corresponding contact element 16. The wall sections 24 of each wall element 22 may be arranged in a closed shape around the corresponding contact element 16. In particular, the wall sections 24 may form a substantially cuboid, box-shaped enclosure 26 around the corresponding contact element 16. Between each wall element 22 and the corresponding contact element 16, a reception zone 28 is defined (see
The cover structure 20 further comprises a retractable cover element 30. The cover element 30 may be a single-piece component, preferably molded from resin. Alternatively, the cover element 30 may be manufactured by additive manufacturing and/or made from other electrically insulative materials. For each contact element 16, the cover structure 20 preferably comprises one cover element 30.
Each cover element 30 is movable, preferably slidably movable, within the reception zone 28 between the corresponding wall element 22 and contact element 16. In the reception zone 28, each cover element 30 can be moved into a secured position 32 as shown in
The respective contact element 16 is enclosed by the corresponding cover element 30 in the secured position 32. In particular, the respective contact element 16 is covered by the corresponding contact element 16 in the retraction direction 36 and optionally in a direction perpendicular to the retraction direction 36. When the corresponding cover element 30 is moved into the retracted position 34, at least part of the contact element 16 is neither enclosed nor covered by the corresponding cover element 30.
For securing the cover element 30 in the secured position 32, the corresponding wall element 22 comprises at least one deflectable latch member 38. In particular, the at least one deflectable latch member 38 selectively hinders the cover element 30 from moving into the retracted position 34, as will be described in further detail below.
The at least one deflectable latch member 38 may be a cantilever flap 40 which has a supported end 42 monolithically connected to one of the wall sections 24 and a free end 44 extending against the retraction direction 36, as can be seen in
It is to be understood that the term “deflectable” refers to a property of the at least one latch member 38 according to which the at least one latch member 38 is more elastic, more flexible, more resilient and/or more pliable than the rest of the wall element 22. In other words, a deflection of the at least one latch member 38 requires less force than a comparable deflection of any other part of the wall element 22. Optionally, the at least one latch member 38 may also exhibit a higher elasticity, flexibility, resiliency and/or pliability than any part of the cover element 30.
Further, the wall element 22 may comprise at least two latch members 38 which are arranged opposite to each other with respect to the corresponding contact element 16. In the illustrated exemplary embodiment of
Each latch member 38 may further comprise at least one bevel surface 52, which extends obliquely with respect to the retraction direction 36. The at least one bevel surface 52 may also be formed preferably on the edge 50 of the free end 44 of the corresponding latch member 38 embodied by the cantilever flap 40. Each bevel surface 52 functions as a lead-in chamfer 54 for the mating connector 2 (see
As will be described with reference to
As can be seen in
As can be seen in the sectional view of
In the secured position 32 of each cover element 30, the corresponding contact element 16 is positioned beyond the plate section 72 in the retraction direction 36. Thereby, a certain travel distance of the respective cover element 30 is necessary, until the respective contact element 16 is made accessible.
The cover structure 20 having each cover element 30 in the secured position 32 provides a finger protection for all contact elements 16 according to UL-Standard 60950 and DIN-EN-Standard 60592. The cover structure 20 having at least one cover element 30 in the retracted position 34 still provides at least a finger protection for all contact elements 16 according to DIN-EN-Standard 60592. This will be described in further detail below.
As can be seen in the sectional view of
If the at least one latch member 38 is deflected e.g., away from the corresponding cover element 30, the respective blocking surfaces 46 and blocking features 74 are brought out of alignment and thus do not abut against each other. This way, the corresponding cover element 30 is released and can be moved into the retracted position 34.
According to an alternative embodiment not shown in the figures, the at least one blocking feature may be a notch (not shown) extending through the plate section 72 perpendicularly to the retraction direction 36. Consequently, the at least one blocking surface 46 may be formed e.g., on a stopping protrusion (not shown) extending from the free end 44 of the corresponding latch member 38 and into the at least one blocking feature embodied by the notch. The remaining functionality may be analogous as described above.
As can be seen in
The tab-shaped contact elements 16 shown in the exemplary embodiment of
The cover structure 20 may further comprise a cap element 78, preferably for each contact element 16. The cap element 78 covers at least a tip section 80 of the corresponding contact element 16. In particular, the cap element 78 comprises a top section 82 adjacent to the tip section 80 of the corresponding contact element 16. Said top section 82 covers the tip section 80 in the retraction direction 36. In other words, the top section 82 protects the tip section 80 against access from the retraction direction 36. For this, the top section 82 may be mechanically attached, glued, overmolded or otherwise fixed to the tip section 80.
The cap element 78 may further comprise at least one side section 84 extending along at least one side edge 86 of the corresponding contact element 16. As shown in
The top section 82 of the cap element 78 may exhibit a material width 88 smaller than a material width 90 of the side sections 84 of the cap element 78, the material widths 88, 90 being measured in a direction perpendicular to the retraction direction 36. In particular, the material widths 88, 90 are measured in a direction perpendicular to the contact surfaces 92 of the corresponding contact element 16. Thus, in a cross-section perpendicular to the retraction direction 36, the cap element 78 may exhibit a double T-shaped profile.
The wall element 22 in combination with the cap element 78 forms a finger protection for the corresponding contact element 16. In particular, a finger protection according to DIN-EN-Standard 60592 is established thereby. In other words, a finger probe (not shown) having a dimension as defined in DIN-EN-Standard 60592 is hindered by the wall element 22 and/or the cap element 78 from reaching the contact surfaces 92 of the corresponding contact element 16.
In addition, the wall element 22, the cap element 78 and the cover element 30 in the secured position 32 also jointly form a finger protection for the corresponding contact element 16. In particular, a finger protection according to DIN-EN-Standard 60592 and UL-Standard 60950, respectively, is established thereby. In other words, neither the finger probe having the dimension as defined in DIN-EN-Standard 60592 nor a finger probe 104 having a dimension as defined in UL-Standard 60950 can reach the contact surfaces 92 of the corresponding contact element 16, due to being hindered therefrom by the wall element 22, the cap element 78 and/or the cover element 30 in the secured position 32. This is shown exemplarily in
Each cover element 30 may comprise an orifice 94 for passing the corresponding contact element 16 and/or the corresponding cap element 78 therethrough. The orifice 94 may in particular be a slit 96 extending in the retraction direction 36. The slit 96 is preferably thin enough to prevent entry of any of the finger probes mentioned above. Furthermore, the orifice 94 embodied by the slit 96 may be shaped complementarily to the double T-shaped profile of the cap element 78, as shown in
At least one guiding groove 98 extending along the retraction direction 36 may be formed on the at least one latch member 38. As is shown in
As can further be observed from
For increased stability, the wall elements 22 may be monolithically connected to each other by a connecting wall 100 (see
As can further be seen in
For the respective contact guard 110 to be insertable into the corresponding reception zone 28, the cover element 30 being secured against movement in the secured position 32 has to be released. To achieve this, the mating connector 2 may further comprise the at least one deflection element 56 for deflecting the at least one latch member 38 of the electrical connector 1. The at least one deflection element 56 may be a hump-shaped or prismatic bulge 118 formed on the contact guard 110. Said bulge 118 may comprise the inverse surface 58 described above.
Prior to and/or during the insertion of the respective contact guard 110 into the corresponding reception zone 28, the inverse surface 58 and the bevel surface 52 of the at least one latch member 38 slide along each other. Since these surfaces 52, 58 extend obliquely with respect to the mating direction 14, the movement of the mating connector 2 along the mating direction 14 is transformed into a movement of the latch member 38 perpendicularly to the mating direction 14. In other words, the at least one latch member 38 is wedged aside by the corresponding deflection element 56, thus deflecting the respective latch member 38 away from the corresponding cover element 30. As already described above, such a deflection leads to the respective blocking surfaces 46 and blocking features 74 being brought out of alignment and out of abutment. Hence, the corresponding cover element 30 is released. Preferably, the cover element 30 can only be released this way.
Thereafter, the respective contact guard 110 abuts with its top surface 112 against the plate section 72 of the corresponding cover element 30. Thereby, the cover element 30 is pushed and moved from the secured position 32 to the retracted position 34 during the mating process.
Preferably, the at least one latch member 38 is only deflected, when the at least one deflection element 56 enters the corresponding reception zone 28 of the electrical connector 1. In other words, the at least one latch member 38 is only deflected, when the at least one deflection element 56 is in the access opening 62. As the at least one deflection element 56 is moved away from the access opening 62 and towards the withdrawal zone 66, the at least one deflection element 56 is received within one of the guiding grooves 98 formed on the corresponding latch member 38. In particular, the at least one deflection element 56 is entirely accommodated within the guiding groove 98 and thus does not mechanically interfere with the corresponding latch member 38.
Analogously, each blocking feature 74 embodied by the nib-shaped protrusions 76 is also received and entirely accommodated within one of the guiding grooves 98, so as to not mechanically interfere with the corresponding latch member 38.
If the electrical connector 1 and the mating connector 2 are unmated, in particular when the at least one deflection element 56 exits the reception zone 28 through the access opening 62, the deflection element 56 wedges the respective latch member 38 aside as was the case during the mating process. Further, when the electrical connector 1 and the mating connector 2 are unmated, all cover elements 30 preferably return from the retracted position 34 to the secured position 32, respectively. To achieve this, each cover element 30 may comprise at least one catch section 120 for interacting with a snap element 122 of the mating connector 2. For example, the at least one catch section 120 and snap element 122 may form a connection, such as a snap-fit connection, as can be seen in the sectional view of
The snap elements 122 may be hook-shaped, knob-shaped or rib-shaped projections 124 formed on the mating connector 2 and pointing in the retraction direction 36. Further, the snap elements 122 may be received within the respective catch sections 120. In particular, each catch section 120 may be formed by a side wall 126 of the cover element 30 and a flexible cantilever beam 128 extending parallel to the side wall 126 along the retraction direction 36. The side wall 126 and/or the cantilever beam 128 may have a catching protrusion 130 extending towards the cantilever beam 128 and the side wall 126, respectively. Alternatively, the at least one catch section 120 may be formed by two flexible cantilever beams (not shown) extending parallel to each other. Further, alternatively, the allocations of the snap elements 122 and the catch sections 120 may be inverted between the electrical connector 1 and the mating connector 2.
Upon reception of the respective snap element 122 in the corresponding catch section 120, the snap-fit connection may be established. Said snap-fit connection allows the cover element 30 to closely follow a movement of the mating connector 2 along the retraction direction 36. In particular, the cover element 30 does not move into the retracted position 34 by its own gravity. In other words, the cover element 30 does not fall into the withdrawal zone 66 as long as the snap-fit connection with the mating connector 2 is in place. The cover element 30 only moves into the retracted position 34, when pushed by the mating connector 2, as described above.
Accordingly, the cover element 30 is pulled out of the withdrawal zone 66 and returned to the secured position 32 by the mating connector 2 via the snap-fit connection, when the mating connector 2 is moved against the retraction direction 36 e.g, during the un-mating process. Thereby, an occurrence of a gap between the mating connector 2 and the cover element 30 after the release of the cover element 30 from the secured position 32 is prevented at all times.
To ensure that the respective snap element 122 is not let go by the corresponding catch section 120, unless the cover element 30 is in the secured position 32, each catch section 120 may exhibit a higher rigidity when the cover element 30 is in the retracted position 34 than when the cover element 30 is in the secured position 32. This can be achieved as follows:
In the retracted position 34 of the cover element 30, the cantilever beam 128 is positioned within the withdrawal zone 66. In particular, the clear width 70 of the withdrawal zone 66 described above is such that the cantilever beam 128 rests against the wall element 22. Thus, the cantilever beam 128 is limited in its movement or entirely loses its flexibility. Thereby, the snap element 122 is firmly held within the catch section 120.
In this case, the terms “firmly held” refer to a state where a force required for pulling the snap element 122 out of the corresponding catch section 120 is larger than the weight force of the cover element 30 and/or the friction force acting between the cover element 30 and the rest of the electrical connector 1.
In the secured position 32 of the cover element 30, the cantilever beam 128 is positioned within the reception zone 28. Due to the larger clear width 68 of the reception zone 28 compared to the withdrawal zone 66, as described above, the cantilever beam 128 is spaced apart from the wall element 22 and thus maintains its flexibility. Consequently, the snap element 122 can easily enter or leave the catch section 120.
It is to be understood that the terms “easily enter or leave” refer to a state where the force required for inserting the snap element 122 into the corresponding catch section 120 as well as pulling the snap element 122 out of the corresponding catch section 120 is smaller than a resisting force acting between the cover element 30 and the rest of the electrical connector 1. Said resisting force may for example derive from the blocking features 74 and/or from hook-shaped anchoring latches 132 (see
Additionally or alternatively, a resilient position restoration element (not shown), such as a coil spring can be used to bias the cover element 30 towards the secured position 32 and out of the retracted position 34. Optionally, one of the electrical connector 1 and mating connector 2 may comprise a lever 134 for facilitating the mating process (see
In addition, those areas in which it is believed that those of ordinary skill in the art are familiar, have not been described herein in order not to unnecessarily obscure the invention described. Accordingly, it has to be understood that the invention is not to be limited by the specific illustrative embodiments, but only by the scope of the appended claims.
It should be appreciated for those skilled in this art that the above embodiments are intended to be illustrated, and not restrictive. For example, many modifications may be made to the above embodiments by those skilled in this art, and various features described in different embodiments may be freely combined with each other without conflicting in configuration or principle.
Although several exemplary embodiments have been shown and described, it would be appreciated by those skilled in the art that various changes or modifications may be made in these embodiments without departing from the principles and spirit of the disclosure, the scope of which is defined in the claims and their equivalents.
As used herein, an element recited in the singular and proceeded with the word “a” or “an” should be understood as not excluding plural of the elements or steps, unless such exclusion is explicitly stated. Furthermore, references to “one embodiment” of the present disclosure are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. Moreover, unless explicitly stated to the contrary, embodiments “comprising” or “having” an element or a plurality of elements having a particular property may include additional such elements not having that property.
| Number | Date | Country | Kind |
|---|---|---|---|
| 202141006230 | Feb 2021 | IN | national |
