Patent Application
20140273628
The subject matter herein relates generally to right angle header assemblies.
Increased fuel costs and increased efforts at reducing environmental pollution have lead the automotive industry towards electric and hybrid electric vehicles (HEV). The electrical systems of these vehicles include components that operate at high voltages and require high voltage pathways including connectors. For example, some known vehicular electrical systems include components that operate using up to and beyond 600 volts.
In some current automotive applications, high voltage shielded connector assemblies are used to provide a stable, sealed mechanism and electrical connection between a high voltage plug assembly and a header assembly mounted to an electronic device in a vehicle, such as a heating or air conditioning unit. The assemblies may need to provide robust shielding continuity between the assemblies and/or other components in the device. Due to space requirements or design preferences, the assemblies may need to provide such robust shielding continuity along a 90° bend.
Known 90° connector assemblies for high voltage automotive applications are not without disadvantages. For example, the 90° bend is accomplished in the plug assembly. There is a large amount of room required to mate the plug assembly to the device because the plug is mated in a direction perpendicular to the panel of the device. Such connector assemblies face certain design challenges. For example, problems exist with routing a high voltage circuit and a high voltage interlock circuit through the 90° bend, and routing a shield circuit through the same 90° bend. Another problem is accomplishing the 90° bend in a small package that can be mass produced.
A need remains for a right angle panel-mount header assembly designed for high voltage application.
In one embodiment, a high voltage (HV) header assembly includes an outer housing and HV contacts. The outer housing has a right angle body including a first segment and a second segment oriented perpendicularly to the first segment. The first segment has a mating interface at a distal end thereof defining a socket for mating with a plug assembly. The second segment has a mounting flange at a distal end thereof configured to be mounted to a device. The second segment extends from the first segment such that the mounting flange is oriented perpendicularly to the mating interface. The body defines a right angle chamber extending through the first and second segments between the mating interface and the mounting flange. The chamber has first and second openings therethrough in the first and second segments, respectively. The first and second openings are perpendicular to one another. The HV contacts are received in the chamber of the outer housing. The HV contacts are configured to electrically connect to plug contacts of the plug assembly. The HV contacts each have a stem extending at least partially along the first segment. The HV contacts each have a tail extending at least partially along the second segment.
Optionally, the HV header assembly may further include a first shield received within the chamber through the first opening. A first inner housing may be received within the chamber with the first shield surrounding at least a portion of the first inner housing. The first inner housing may define channels to house the HV contacts. Optionally, the HV header assembly may further include a second shield received within the chamber through the second opening. The second shield may be electrically connected to the first shield. The second shield may be oriented perpendicularly to the first shield within the chamber. Optionally, the HV header assembly may further include a second inner housing received within the chamber. The second shield may surround at least a portion of the second inner housing. The second inner housing may define cavities to house HV terminals. The HV terminals may be electrically connected with the HV contacts. Optionally, the HV header assembly may further include high voltage interlock (HVIL) contacts received in the chamber of the outer housing. The HVIL contacts are configured to electrically connect to HVIL plug contacts of the plug assembly.
In another embodiment, a HV header assembly includes an outer housing, a contact subassembly, and a terminal subassembly. The outer housing has a right angle body comprising a first segment and a second segment oriented perpendicularly to the first segment. The body defines a right angle chamber extending through the first and second segments. The chamber has first and second openings therethrough in the first and second segments, respectively. The contact subassembly is received in the chamber through the first opening. The contact subassembly includes a first shield, a first inner housing at least partially surrounded by the first shield, HV contacts received within a first set of channels within the first inner housing, and HVIL contacts received within a second set of channels within the first inner housing. The terminal subassembly is received in the chamber through the second opening. The terminal subassembly includes a second shield, a second inner housing at least partially surrounded by the second shield, HV terminals received within a first set of cavities within the second inner housing, and HVIL terminals received within a second set of cavities within the second inner housing. The contact subassembly is coupled to the terminal subassembly at a separable interface within the chamber. The contact subassembly is oriented perpendicularly to the terminal subassembly.
The plug assembly 104 may house HV electrical conductors (not shown). The electrical conductors may include wires that extend from the plug assembly 104 through a cable 108. The cable 108 may electrically connect the plug assembly 104 to a printed circuit board and/or terminals of another device, such as a battery, a motor, and the like. Optionally, the plug assembly 104 may connect directly to the other device, without the use of a cable. When the plug assembly 104 is mated with the HV header assembly 100, the electrical components (not shown) within the device 102 are electrically connected to the other device and may communicate with and/or transfer power to/from the device 102.
In an exemplary embodiment, the HV header assembly 100 has a right angle shape. As used herein, “right angle” generally refers to two planes that are generally perpendicular and/or have a relative angle of approximately 90°, though the angle does not have to be exact. Upon moving the plug assembly 104 towards the HV header assembly 100 for mating, the plug assembly 104 is moved in a plugging direction 110. The plugging direction 110 is generally parallel to the plane defined by the panel 106. The right angle shape of the HV header assembly 100 may be useful in applications with limited clearance between the panel 106 and an obstruction (not shown) near the non-panel side of the HV header assembly. For example, other devices or other components may be mounted adjacent the device 102 that leave relatively tight clearances along the sides of the device 102. However, the plug 104 may be successfully mated along the plugging direction 110 and unmated in the opposite direction in such tight spaces because the plugging direction 110 is parallel to the panel 106.
The HV header assembly 100 may be sized to extend outward from the panel 106 no farther than a traditional straight or 180° panel-mount header extends. Therefore, the area occupied, or “footprint”, of the mounted HV header assembly 100 may be the same or less than traditional straight header connectors. Furthermore, because the HV header assembly 100 includes a right angle bend, the plug assembly 104 need not be specially designed for right angle connections. For example, the HV header assembly 100 may be configured to mate with the same plug assembly that mates with straight or 180° header connectors.
The HV header assembly 100 includes a contact subassembly 216 and a terminal subassembly 218. The contact subassembly 216 is configured to be received in the chamber 210 through the first opening 212. The terminal subassembly 218 is configured to be received in the chamber 210 through the second opening 214. The contact subassembly 216 may be oriented generally perpendicularly to the terminal subassembly within the chamber 210.
Optionally, the first segment 206 may be oriented at an angle more or less than 90° relative to the second segment 208, while the body 204 still defines a right angle chamber 210 that receives the contact subassembly 216 and the terminal subassembly 218 in perpendicular relation to each other. The contact subassembly 216 need not be parallel to the first segment 206 of the outer housing 202, and the terminal subassembly 218 need not be parallel to the second segment 208. In other embodiments, the HV header assembly 100 may be configured to dispose the contact subassembly 216 at an angle more or less than 90° relative to the terminal subassembly 218.
The outer housing 202 includes a mounting flange 226 at a distal end of the second segment 208. The mounting flange 226 is configured to mount to the panel 106 of the device 102 (shown in
To mount the HV header assembly 100 to the panel 106 of the device 102 (both shown in
In an exemplary embodiment, the outer housing 202 is formed as a single piece. For example, the outer housing 202 may be composed of plastic and manufactured in a mold. The first and second segments 206, 208 are integral and part of the one-piece body. The first and second segments 206, 208 are co-molded. Alternatively, the outer housing 202 may be composed of other materials, such as metal or ceramic, and may be formed by processes other than molding.
In an exemplary embodiment, the contact subassembly 216 includes a first shield 236, a first inner housing 238, HV contacts 240, and HVIL contacts 242. The terminal subassembly 218 includes a second shield 268, a second inner housing 302, HV terminals 286, and HVIL terminals 300. In alternative embodiments, the contact subassembly and terminal subassembly may include different components than the contact subassembly 216 and terminal subassembly 218, such as, for example, replacing the HVIL contacts and HVIL terminals with a different power circuit.
The shield 236 of the contact subassembly 216 extends between a front 244 and a rear 246. The shield 236 has a shield cavity 248 extending between the front 244 and the rear 246. The inner housing 238 is configured to be received in the shield cavity 248 such that at least a portion of the inner housing 238 is surrounded by the shield 236. In an exemplary embodiment, the shield 236 is manufactured from a conductive material such as metal. The shield 236 may be stamped and formed into a desired shape. The shield 236 provides electrical shielding around a portion of the inner housing 238 and provides electrical shielding around the HV contacts 240 and HVIL contacts 242. The shield 236 may provide shielding from electromagnetic interference (EMI), or other types of interference.
The shield 236 may include one or more deflectable beams 250 at the rear 246. The deflectable beams 250 may be partially cut-out and/or bent sections of the shield 236. In an exemplary embodiment, deflectable beams 250 are located along both sides 252 of the shield 236. Upon mating the contact subassembly 216 to the terminal subassembly 218 within the chamber 210, the deflectable beams 250 may be biased against the second shield 268 of the terminal subassembly 218 to ensure contact with the shield 268. Alternatively, the shield 236 may include more than two deflectable beams 250 located on the sides 252 and/or extending downward from a top 254 and/or bottom 256 of the shield 236. Alternatively, deflectable beams 250 are disposed on shield 268 of the terminal subassembly 218 instead of shield 236.
The shield 236 includes one or more tabs 260 located generally proximate to the rear 246. The tabs 260 may be formed by stamping and bending the tabs 260 out of the surface of the shield 236. In an exemplary embodiment, the tabs 260 are disposed along the top 254 of the shield 236. Alternative embodiments include different configurations of tabs 260. The tabs 260 are used to secure the shield 236 within the outer housing 202. The tabs 260 may interfere with predefined extensions or grooves within the interior surface of the outer housing 202 that defines the chamber 210. Additionally, the interference between the tabs 260 and the extensions or grooves within the outer housing 202 may provide a stop point when the contact subassembly 216 is loaded into the chamber 210. Alternatively, the header subassembly 100 may be designed such that the loading stop point for the contact subassembly 216 is the point at which the rear 246 of the shield 236 contacts an inner surface of the second segment 208 of the outer housing 202.
In an exemplary embodiment, the shield 236 defines an exposed region 258 along the bottom 256 of the shield 236 proximate to the rear 246. The exposed region 258 may be a cut-out or recessed portion of the bottom 256 of the shield 236 that is configured to allow the contact subassembly 216 to couple to the terminal subassembly 218 at a right angle within the chamber 210. When mated, the exposed region 258 provides an opening that exposes the first shield cavity 248 to a cavity 270 within the second shield 268 of the terminal subassembly 218, resulting in a combined right angle shield cavity.
The first inner housing 238 includes a front 262 and a rear 264. The inner housing 238 has an inner cavity 266 at the front 262. The inner cavity 266 leads to one or more contact channels 404, 406 (shown in
The HV contacts 240 and HVIL contacts 242 are configured to electrically connect to respective plug contacts of the plug assembly 104 (shown in
The HV contacts 240 have a mating end 274 and a terminating end 276. The mating end 274 is configured to electrically connect to corresponding HV plug contacts. The terminating end 276 is configured to electrically connect to HV terminals 286 of the terminal subassembly 218. In an exemplary embodiment, the terminating end 276 is oriented perpendicularly to the mating end 274. For example, the terminating end 276 may have a tail 278 extending perpendicularly to a longitudinal axis 280 of the contact subassembly 216. The mating end 274 has a stem 282 that extends parallel to the longitudinal axis 280 and perpendicular to the tail 278. The stem 282 may include one or more retention features 284, for example raised serrated ridges, designed to provide additional interference within the respective channel (not shown) of the inner housing 238 to prohibit unintentional movement within the channel.
The HV contacts 240 may be manufactured from a conductive material such as metal. The HV contacts may be stamped and formed into a desired shape. In an exemplary embodiment, the HV contacts 240 are planar. In an exemplary embodiment, the stem 282 is longer than the tail 278. The tail 278 may be a blade or a pin. Alternatively, the tail may be formed as a socket. In an alternative embodiment, the HV contacts are linear and/or do not have a tail at a terminating end.
The HVIL contacts 242 have a mating end 287 and a terminating end 288 oriented perpendicularly to the mating end 287. The mating end 287 is configured to electrically connect to corresponding HVIL plug contacts, and the terminating end 276 is configured to electrically connect to HVIL terminals 300 of the terminal subassembly 218. Like the HV contacts 240, the terminating end 276 of the HVIL contacts 242 may include a tail 290 that extends perpendicularly to the longitudinal axis 280. The mating end 287 has a stem 292 that extends parallel to the longitudinal axis 280 and perpendicular to the tail 278. Optionally, the stem 292 may include a first segment 294 and a second segment 296 joined together through sonic welding, crimping, and the like. Each HVIL contact 242 may include one or more retention features 298 that extend from a plane of the HVIL contacts 242 for providing additional interference within the respective channel (not shown) of the inner housing 238. The HVIL contacts 242 may be stamped and formed from a conductive material such as metal. In an exemplary embodiment, the tail 290 is shorter than the stem 292 and shaped as a pin or a blade configured to be received within a socket of the HVIL terminal 300. Alternatively, the tail may not be perpendicular to the axis 280 and/or has a socket configured to receive a pin or blade of an HVIL terminal.
The second shield 268 of the terminal subassembly 218 extends between a top 304 and a bottom 306, and has the second shield cavity 270 extending between the top 304 and the bottom 306. The inner housing 302 is received in the shield cavity 270 such that at least a portion of the inner housing 302 is surrounded by the shield 268. In an exemplary embodiment, the shield 268 is manufactured from a conductive material such as metal. The shield 268 may be stamped and formed into a desired shape. The shield 268 provides electrical shielding around a portion of the inner housing 302 from EMI or other types of interference. The shield 268 provides electrical shielding around the HV terminals 286 and HVIL terminals 300.
The shield 268 includes one or more ground fingers 308 extending from the bottom 306. The ground fingers 308 are configured to engage the panel 106 of the device 102 (both shown in
The shield 268 may include one or more tabs 310 to secure the shield 268 within the outer housing 202, and to secure the second inner housing 302 to the shield 268. The tabs 310 may be formed by stamping and bending. In an exemplary embodiment, the tabs 310 are disposed along a front side 312 of the shield 268. Alternative embodiments include different tab 310 configurations. In an exemplary embodiment, the shield 268 defines an exposed region 314 along the front side 312 of the shield 268 proximate to the top 304. The exposed region 314 is configured to interface with the exposed region 258 of the first shield 236 when the terminal subassembly 218 is coupled to the contact subassembly 216 at a right angle within the chamber 210. The exposed regions 258, 314 interface at the opening between the first shield cavity 248 and the second shield cavity 270 to define a continuous, right angle shield cavity. The shields 236, 268 are configured to provide full 360° shielding of the electrical components throughout the length of the chamber 210 including the right angle (as shown in
The second inner housing 302 includes a top 316 and a bottom 318. The inner housing 302 may define a first set of cavities 320 configured to receive the HV terminals 286 and a second set of cavities 322 configured to receive the HVIL terminals 300. The cavities 320, 322 may extend from the bottom 318 to the top 316 of the inner housing 302. The inner housing 302 may be a dielectric material, such as plastic, ceramic, rubber, glass, and the like, to electrically insulate the individual terminals 286, 300. In an exemplary embodiment, the inner housing 302 includes one or more locking surfaces 324, such as a depression, configured to engage one or more inward-extending tabs 310 to secure the inner housing 302 within the shield 268. Alternatively, the locking surface may be a protrusion configured to extend into a bump or opening in the shield 268. In an exemplary embodiment, the inner housing 302 includes a flange 326 proximate to the bottom 318. The flange 326 acts as a stop for loading the inner housing 302 into the shield 268 and/or into the outer housing 202.
The HV terminals 286 and HVIL terminals 300 are configured to electrically connect to respective HV and HVIL contacts 240, 242 to transfer high voltage power and/or data through the right angle turn in the HV header assembly 100. The HV terminals 286 may be generally linear with a contact end 328 and a cable end 330. The contact end 328 is configured to electrically connect to the terminating end 276 of the HV contact 240. The cable end 330 is configured to mount to one or more insulated electrical cables 332 leading to electrical components (not shown) within the device 102 (shown in
The HV terminals 286 may be manufactured from a conductive material such as metal. The HV terminals 286 may be stamped and formed into a desired shape. The HV terminals 286 may include one or more retention features 338 to provide additional interference within the cavities 320 of the inner housing 302 to prohibit unintentional movement within the cavities 320.
The HVIL terminals 300 have a contact end 340 and a mounting end 342. The HVIL terminals 300 may be generally linear with the contact end 340 configured to electrically connect to the HVIL contacts 242 and the mounting end 342 cable-mounted to an electrical component (not shown) of the device 102 (shown in
Optionally, the HV header assembly 100 may include a seal 350. The seal 350 may be a round loop, such as an O-ring gasket and may be formed of plastic, rubber, or another at least partially compressible material. In an exemplary embodiment, the seal 350 may be seated in a groove (not shown) along the bottom face 228 of the mounting flange 226 around the second opening 214 to the chamber 210. The seal 350 may be designed to be compressed between the bottom face 228 and the panel 106 (shown in
The HV contacts 240 may be loaded into the inner housing 238 in a loading direction 408 into a first set of contact channels 404 within the inner housing 238. In an exemplary embodiment, the HV contacts 240 are loaded, mating end 274 first, into the channels 404 from the rear 264 of the inner housing 238 to the front 262. The channels 404 are sized to receive the linear stems 282 of the HV contacts 240. The tails 278 are configured to extend from the channels 404. The tails 278 may provide a loading stop point for the HV contacts 240. Once loaded, the mating ends 274 of the HV contacts 240 are positioned within the inner cavity 266 of the inner housing 238 and poised for mating with plug contacts (not shown) of the plug assembly 104 (shown in
In an exemplary embodiment, the contact channels 406 for the HVIL contacts 242 are located between the contact channels 404 housing the HV contacts 240. For example, the contact channels 406 may be stacked vertically with the contact channels 404 arranged on opposite sides of the contact channels 406 like bookends. Due to vertical stacking of the contact channels 406, in an exemplary embodiment, the stem 292 and/or tail 290 of the upper HVIL contact 242A (i.e., the HVIL contact 242 furthest from the mounting flange 226 (shown in
It should be noted that the order of the figures presented does not indicate a required order of assembly of the contact subassembly 216, nor do the assembly steps discussed constitute all possible steps or necessary steps to assemble the contact subassembly 216.
It is to be understood that the above description is intended to be illustrative, and not restrictive. For example, the above-described embodiments (and/or aspects thereof) may be used in combination with each other. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from its scope. Dimensions, types of materials, orientations of the various components, and the number and positions of the various components described herein are intended to define parameters of certain embodiments, and are by no means limiting and are merely exemplary embodiments. 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 appended claims, along with the full scope of equivalents to which such claims are entitled. In the appended claims, the terms “including” and “in which” are used as the plain-English equivalents of the respective terms “comprising” and “wherein.” Moreover, in the following claims, the terms “first,” “second,” and “third,” etc. are used merely as labels, and are not intended to impose numerical requirements on their objects. Further, the limitations of the following claims are not written in means—plus-function format and are not intended to be interpreted based on 35 U.S.C. §112, sixth paragraph, unless and until such claim limitations expressly use the phrase “means for” followed by a statement of function void of further structure.
