Patent Application
20230387622
This application claims benefit of priority to European Patent Application No. 22175707.3 filed on May 27, 2022, the entire disclosure of which is hereby incorporated by reference.
The present disclosure relates to an electrical connector for connecting an electrical conductor to a counter-connector.
In modern vehicles, the transmission of electric power and signals is becoming increasingly important. This particularly applies to electric vehicles, whose functionality is highly based on a stable energy supply from a charging inlet to a battery and from the battery to one or more electric devices, such as electrical engines.
To transmit electric power and signals, wiring harnesses are usually utilized in the automotive industry. A wiring harness, also known as a cable harness, is an assembly of electric conductors such as busbars, cables and/or wires. The wiring harnesses are prefabricated and then mounted into a vehicle and connected to respective electric interfaces. In hybrid and electric vehicles high electric currents and high voltages are often transmitted by means of busbars. The busbars may form part of the wiring harness and/or of the further electric architecture of the vehicle which may be e.g., connected to the wiring harness. Exemplarily, busbars may be directly attached to the battery of the vehicle as an interface for further electric connections. Moreover, a busbar provided in the wiring harness may serve to conduct electric power from a battery of the vehicle to an electric engine of the vehicle and/or from a charging port to the battery.
For electric vehicles, it is crucial that a busbar, which for example is supposed to provide energy from the battery to the vehicle, but also any other electrical conductor provides a sufficient safety standard. Here, the safety of the connection refers not only to the reliability of the connection during use, but also to the safety of handling the connection. Particularly the aspect of safety includes that the connection must be safe to touch so that no danger arises from high voltages and/or currents in a high-voltage system such as an electrified vehicle. Thereby contact safety must be ensured in the connected state and the unconnected state. Exemplarily, in the event of an inspection or in the event of servicing, e.g., battery module connectors need to be safely handled without the need to provide special tools or complicated safety procedures. Accordingly, it is a general objective of the present disclosure to provide an electrical connector that allows for a safe handling.
An existing solution for providing a safe connection between busbars is described in document EP 3 419 119 A1. This document refers to a module connector, for batteries of vehicles with an electric drive. The module connector has two connection parts which can be electrically connected to one another in an electrically conductive manner. Each connection part is provided with a touch protection having an outer, electrically insulated collar and an electrically insulated protection pin which is surrounded by the collar. Particularly, a current bridge which electrically connects two conductor points and which the collar and protection pin project beyond is located at least one connection part between the collar and protection pin. Hence, the user is prevented from touching the current bridge by means of the collar and the protection pin.
EP 3 419 119 A1 suggests that the protection pin is attached to an affixing element that serves to mechanically connect the two connection parts. For this configuration multiple disadvantages have been identified.
First, the protection pin can be damaged and/or fall off the affixing element during connecting the two connection parts, particularly since the affixing element can be exposed to complex motions and/or mechanical loads which may damage and/or remove the protection pin. Exemplarily the insulative material may be damaged and/or retained by a thread of the affixing element. This bears the risk that during inspection or servicing when the connection parts are separated the protection is insufficient and a security risk exists.
Second, the module connector requires specific affixing elements which include the protection pin, i.e., an insulation. Exemplarily a screw without insulative provisions cannot be utilized.
Third, since the protection pin is attached to a tip of an affixing element the length of the connection which is required in mating direction is increased. This is particularly disadvantageous for applications in confined spaces.
Fourth, the module connector of EP 3 419 119 A1 has drawbacks regarding mountabiliy. In particular, the assembly sequence is complicated to perform by a worker.
Thus, it is an object of the present disclosure to provide an electrical connector that overcomes the aforementioned drawbacks at least partially.
These objects are achieved, at least partly, by an electrical connector according to the present disclosure. Particularly, the object is achieved by an electrical connector for connecting an electrical conductor to a counter-connector, particularly for connecting a busbar of an electrical vehicle to the counter-connector. The electrical conductor may include a busbar and/or a terminal of a busbar.
The electrical connector includes a connector housing configured for mating with a corresponding counter-connector. Thereby a receptacle, such as an opening, configured for at least partially receiving the counter-connector may be formed in the connector housing. The connector housing may include a bent sheet metal and/or a plastic, particularly a reinforced plastic. Moreover, the connector housing may be manufactured by casting or injection molding. Further, it is understood that the connector housing may include a plurality of parts. Exemplarily, the connector housing may include an inner part and a surrounding part which e.g., prevents the penetration of water and/or dust.
Further, the electrical connector includes an electrical contacting means being arranged in the connector housing and configured for electrical contact with the electrical conductor. The electrical contacting means is further configured for establishing an electrical contact with the counter-connector. Exemplarily, the electrical contacting means may be arranged in the above-mentioned receptacle that may be formed in the connector housing. Moreover, the electrical contacting means may be shaped for contacting the electrical conductor by means of a planar contact. Exemplarily, the electrical contacting means may have a substantially hollow cylindrical shape with a through hole in an axial direction of the hollow cylindrical shape. Thereby a first flat surface of the hollow cylindrical shape may be arranged for contacting the electrical conductor, particularly the terminal of the busbar. Further, a second flat surface of the hollow cylindrical shape may be arranged for contacting the electrical contacting means of the counter-connector. The electrical contacting means may include a conductor material. The conductor material may include at least one of the following: copper, aluminum, a copper based alloy and/or an aluminum based alloy. Further, the conductor material may include brass. Further, the electrical contacting means may be attached to the connector housing by means of a form-fit connection and/or a frictional connection.
Moreover, the electrical connector includes an insulative sleeve attachable to the electrical contacting means, wherein the insulative sleeve is shaped to prevent a finger of a human from touching the electrical contacting means. A sleeve according to the present disclosure may be referred to as a tubular part, such as a hollow axle and/or a bushing, configured to fit over another part. It is understood that the insulative sleeve may be shaped to prevent a finger of a human from touching the electrical contacting means by configuring a length, an outer diameter, and/or an inner diameter of the insulative sleeve. Thereby it is understood that the insulative sleeve may need to be shaped in accordance with the connector housing to prevent finger contact. The insulative sleeve may primarily consist of an insulative material. Exemplarily, the insulative material may include a plastic, particularly a reinforced plastic. The insulative sleeve may be injection molded, milled, and/or pressed. Touch-protection against finger contact according to the present disclosure may be defined according to IPxxB as per ISO 20653.
Exemplarily, in an assembled state where the insulative sleeve is attached to the electrical contacting means, the insulative sleeve may limit the accessibility for a human finger of the above-mentioned receptacle that may be formed in the connector housing and in which the electrical contacting means may be arranged. Further exemplarily, in the assembled state, the insulative sleeve may form a gap with the connector housing. This gap may be configured such that a finger of a human cannot reach the electrical contacting means in the connector housing, whereas an electrical counter-contacting means of the counter-connector may contact the electrical contacting means. Particularly, the connector housing may include an outer, electrically insulated collar, wherein in an assembled state the insulative sleeve is surrounded by the electrically insulated collar. Thereby, the electrical contacting means which the collar and the insulative sleeve project beyond in mating direction is located between the collar and insulative sleeve. Hence, contact with the electrical contacting means by a human finger may be avoided. Even further exemplarily, by providing the insulative sleeve it is also possible to protect an element being arranged inside the insulative sleeve against finger contact.
Furthermore, with the insulative sleeve being attachable to the electrical contacting means, in an assembled condition a movement and/or mechanical loading of the insulating sleeve during mating the electrical connector to the counter-connector can be reduced compared to the case when an insulation is provided on an affixing element configured for affixing the electrical connector to the counter-connector. Hence, a risk of damaging and/or removing the insulative sleeve is decreased. Exemplarily, when an insulation is provided on a tip of a screw or on a threaded sleeve for affixing the electrical connector to a counter-connector, the screw or the threaded sleeve are exposed to complex motions and/or mechanical loads which may damage and/or remove the insulation.
The insulative sleeve may include a substantially hollow cylindrical shape, wherein the electrical contacting means may have a through-hole shaped to at least partially receive the insulative sleeve therein. With this configuration an affixing element configured for affixing the electrical connector to the counter-connector may be introduced through the electrical contacting means, wherein the affixing element does not require an insulation. Exemplarily a screw without insulative provisions may be utilized.
The term “substantially” according to the present application may refer to the aspect that not the geometrically strict form is required, but e.g., tolerance-related deviations are also possible.
The electrical contacting means and the insulative sleeve may extend in a mating direction of the electrical connector in an assembled condition, and the insulative sleeve may extend further in the mating direction than the electrical contacting means, preferably by the mating direction length of the electrical contacting means multiplied by at least 0.2, further preferably by at least 0.5, even further preferably by at least 0.7, and most preferably by at least 1.0. By the insulative sleeve extending further in the mating direction than the electrical contacting means a finger contact of the electrical contacting means which is arranged in the connector housing may be avoided. This is as a finger may about the insulative sleeve and the connector housing, e.g., the above-mentioned electrically insulated collar, before contacting the electrical contacting means inside the connector housing. The particularly above-mentioned relative lengths have proven to allow for a sufficient protection.
The insulative sleeve may include a mating end with a hollow opening, wherein the hollow opening has a diameter that protects the inside of the insulative sleeve at least partially against finger contact according to IPxxB as per ISO 20653. The mating end may be defined as the end of the insulative sleeve which is inserted into the counter-connector first during mating. By the insulative sleeve including a mating end with a hollow opening, an affixing element which does not require an insulation, such as a screw, may be arranged inside the insulative sleeve, while finger contact with the affixing element can be avoided. Further, a counter-affixing element of the counter-connector may be introduced into the insulative sleeve for mating with the affixing element.
The insulative sleeve may include fixing means for attaching the insulative sleeve to the electrical contacting means, wherein a through hole may be formed through the insulative sleeve and the electrical contacting means such that an affixing element configured for affixing the electrical connector to the counter-connector is arrangeable at least partially inside the insulative sleeve. When the insulative sleeve is attached to the electrical contacting means, the fixing means may avoid retracting the insulative sleeve from the electrical contacting means. Since the affixing element is arrangeable at least partially inside the insulative sleeve, affixing elements which do not need to be insulated may be utilized. Further, since no insulation needs to be attached to the tip of the affixing element the length of the electrical connector which is required in mating direction may be reduced. Moreover, by the insulative sleeve being attachable to the electrical contacting means, in an assembled condition a movement and/or mechanical loading of the insulating sleeve during mating the electrical connector to the counter-connector can be reduced compared to the case when an insulation is provided on the affixing element configured for affixing the electrical connector to the counter-connector. Hence, a risk of damaging and/or removing the insulative sleeve is decreased. Exemplarily, when an insulation is provided on a tip of a screw or a threaded sleeve for affixing the electrical connector to the counter-connector, the screw or the threaded sleeve are exposed to complex motions and/or mechanical loads which may damage and/or remove the insulation.
The fixing means may include at least one outer latching arm, configured for establishing a snap connection with the electrical contacting means in an assembled condition. The fixing means may include at least one protrusion for establishing a form-fit connection with a respective undercut of the electrical contacting means.
The electrical connector may include an affixing element being configured for affixing the electrical connector to the counter-connector, wherein the affixing element may be arranged at least partially inside the insulative sleeve when assembled. Preferably the insulative sleeve is configured such that the affixing element is protected against finger contact according to IPxxB as per ISO 20653. It is understood that the protection against finger contact according to IPxxB as per ISO 20653 may be achieved by a respective diameter and/or length of the insulative sleeve. Nevertheless, it is further understood that also the affixing element may be configured, e.g., in length and/or diameter such that the affixing element is protected against finger contact according to IPxxB as per ISO 20653. Further, since no insulation needs to be attached to the tip of the affixing element for finger contact protection the length of the electrical connector which is required in mating direction may be reduced. Moreover, by the insulative sleeve being attachable to the electrical contacting means, in an assembled condition a movement and/or mechanical loading of the insulating sleeve during mating the electrical connector to the counter-connector can be reduced compared to the case when an insulation is provided on the affixing element. Hence, a risk of damaging and/or removing the insulative sleeve is decreased. Exemplarily, when an insulation is provided on a tip of a screw or a threaded sleeve for affixing the electrical connector to a counter-connector the screw, or the threaded sleeve are exposed to complex motions and/or mechanical loads which may damage and/or remove the insulation.
The insulative sleeve may be configured such that the affixing element is affixable to a counter-affixing element of the counter-connector inside the insulative sleeve. Hence, both affixing elements may be protected, e.g., against dust and/or humidity, inside the insulative sleeve.
Further, the affixing element may be a screw and the counter-affixing element may be a threaded sleeve. Hence, a sufficient fixation may be achieved that is required for connecting busbars in vehicles.
The connector housing may include a cover which in an open state allows the insertion of an affixing element. Hence, when the cover is closed, a further protection against finger contact with an affixing element being arranged inside the connector housing may be provided. Further, by the cover which in an open state allows the insertion of an affixing element, the mountability may be improved, as the electrical connector allows for being provided in a pre-assembled state where the affixing element may still be introduced.
The insulative sleeve may be attached to the electrical contacting means, and the connector housing may include:
Exemplarily, if the electrical conductor which is to be inserted includes a busbar terminal with a rectangular cross-section, the shape of the first recess may correspond at least partially to that of the busbar terminal with rectangular cross-section. Further exemplarily, if the affixing element which is to be inserted includes a screw, the shape of the second recess may correspond at least partially to that of the screw. Moreover, the first recess and the second recess may have an intersecting portion. Hence, the affixing element, when inserted, may protrude through the electrical conductor when inserted. The configuration described above may allow that the electrical connector does not require a specific affixing element which includes an insulation. Exemplarily, a screw without insulative provisions can be utilized. Further, since no insulation needs to be attached to the tip of the affixing element the length of the connection which is required in mating direction may be decreased. This is particularly advantageous for applications in confined spaces. Moreover, mountability may be improved. This is as the electrical connector allows for being provided in a pre-assembled state where only the electrical conductor, e.g., the busbar terminal, and the affixing element need to be inserted and fixed to the connector housing.
Further, the first recess and the second recess may be configured such that an insertion direction for the affixing element is substantially perpendicular to an insertion direction for the electrical conductor. Hence, manufacturing of the electrical conductor may be improved, as the affixing element may be inserted into a through hole of the electrical conductor, wherein the through hole is perpendicular to the insertion direction of the electrical conductor.
The insulative sleeve may include at least one inner latching arm, configured for establishing a snap connection with the affixing element in an assembled condition. Particularly, the at least one inner latching arm may include at least one protrusion for establishing a form-fit connection with a respective recess of the affixing element. Hence, the insulative sleeve may retain the affixing element to the electrical connector. Further, the at least one inner latching arm may allow for a positioning of the affixing element relative to the electrical connector. Moreover, the affixing element may include at least two recesses which allow for the affixing element to be arranged in two different positions relative to the electrical connector.
The insulative sleeve may include at least one stopper protrusion, wherein the stopper protrusion abuts the electrical contacting means in an assembled condition. The at least one stopper protrusion is preferably arranged at an outer circumference of the insulative sleeve. The at least one stopper protrusion may avoid a further insertion of the insulative sleeve into the electrical contacting means against the mating direction. Hence, the above-mentioned fixing means together with the at least one stopper protrusion may allow for an improved fixation of the insulative sleeve to the electrical contacting means.
The electrical connection means may include a bushing, wherein in an assembled condition the insulative sleeve may be arranged at least partially in the bushing. Hence, the inside of the bushing may be insulated against an affixing element being arranged inside the insulative sleeve.
The present invention is now described, by way of example with reference to the accompanying drawings, in which:
As is understood from
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It is understood that the insulative sleeve 250 of the counter-connector 200 is rotated by 45° around its axis in the view of
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The insulative sleeve 150, as depicted in
Many other embodiments and modifications within the spirit and scope of the claims will be apparent to those of skill in the art upon reviewing the above description. The scope of the invention should, therefore, be determined with reference to the following claims, along with the full scope of equivalents to which such claims are entitled.
As used herein, ‘one or more’ includes a function being performed by one element, a function being performed by more than one element, e.g., in a distributed fashion, several functions being performed by one element, several functions being performed by several elements, or any combination of the above.
It will also be understood that, although the terms first, second, etc. are, in some instances, used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first contact could be termed a second contact, and, similarly, a second contact could be termed a first contact, without departing from the scope of the various described embodiments. The first contact and the second contact are both contacts, but they are not the same contact.
The terminology used in the description of the various described embodiments herein is for the purpose of describing embodiments only and is not intended to be limiting. As used in the description of the various described embodiments and the appended claims, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will also be understood that the term “and/or” as used herein refers to and encompasses all possible combinations of one or more of the associated listed items. It will be further understood that the terms “includes”, “including”, “includes”, and/or “including,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
As used herein, the term “if” is, optionally, construed to mean “when” or “upon” or “in response to determining” or “in response to detecting,” depending on the context. Similarly, the phrase “if it is determined” or “if [a stated condition or event] is detected” is, optionally, construed to mean “upon determining” or “in response to determining” or “upon detecting [the stated condition or event]” or “in response to detecting [the stated condition or event],” depending on the context.
Additionally, while terms of ordinance or orientation may be used herein these elements should not be limited by these terms. All terms of ordinance or orientation, unless stated otherwise, are used for purposes distinguishing one element from another, and do not denote any order of arrangement, order of operations, direction or orientation unless stated otherwise.
| Number | Date | Country | Kind |
|---|---|---|---|
| 22175707.3 | May 2022 | EP | regional |
