Electric cable connection system

Abstract

In order to make a cable connection system particularly reliable to operate and compact, an actuator (1) is provided with a rib (123) that is located at an end, guides the actuator along sliding edges (243) of the busbar (2, 2) and actuates a clamping leg (33) of a V-shaped clamping spring (3, 3). This reduces friction and creates space for a collar (613, 613) of the cable (6) at the cable connection end of the rib (123).

Claims

1.-14. (canceled)

15. An electric cable connection system, comprising: a cage-shaped busbar (2, 2) which is fully or at least partially open on a cable connection side to allow an electrical cable (3, 3) to be inserted, including a cage which has two cage walls, namely a first cage wall (21, 21) and a second cage wall (22), and two lateral walls (23) which couple the first cage wall (21, 21) and the second cage wall (22) to each other, wherein the two lateral walls (23) each have a step (24) on a cable insertion side, wherein the step (24) is formed by a slide edge (243) extending in a cable insertion direction and a counter stop edge (242); a V-shaped clamping spring (3, 3), including a retaining leg (31) which is fastened to, or at least held against, the first cage wall (21, 21) of the busbar (2, 2), a spring bend (32) adjoining the retaining leg (31) and, adjoining thereto, a resiliently pivotable clamping leg (33), which can assume a non-actuated state in which it presses a contact portion (62) of an inserted electrical cable (6) against the second cage wall (23) of the busbar (2, 2) in the non-actuated state of the clamping spring (3, 3), in order to electrically couple a core (60) of the electrical cable (6) to the busbar (2, 2) and simultaneously to secure the cable (6) against unintentional withdrawal counter to the cable insertion direction; and which further can assume an actuated state in which it is pivoted, while applying a counterforce, in the cable insertion direction in order to release the cable (6) again as needed for withdrawing it from the cable insertion side; an actuator (1) for transferring the clamping spring (3, 3) from the non-actuated state thereof to an actuated state, wherein the actuator (1) includes two lateral actuating arms (12) and a web (123) which couples the actuating arms (12) via ends thereof and is configured for actuating the clamping leg (33) of the clamping spring (3, 3), wherein the web (123) extends perpendicularly to the slide edges (243) of the lateral walls (22) of the busbar (2, 2) and is in mechanical contact with the slide edges (243), so it is able to slide along the slide edges (243) in order to guide the actuator (1); and the electrical cable (6), which includes the electrically conductive core (60), a transmission portion (61) comprising an electrically insulating sheath (610) which surrounds the core (60) in a radial manner, and the contact portion (62), which is located at an end of the cable (6) to be inserted into the busbar (2, 2) and in which the cable (6) for establishing electrical contact with the busbar (2, 2) does not have an electrically insulating sheath (610), so the core (60) of the cable (6) is not sheathed in this contact portion (62), and a collar (613, 613) which is adjacent to the contact portion (62) and consists of an electrically insulating material; wherein the collar (613, 613) of the electrical cable (6) is arranged on the cable insertion side of the web (123) of the actuator (1).

16. The electric cable connection system as claimed in claim 15, wherein the collar (613) of the cable is formed by an end region of the sheath (610).

17. The electric cable connection system as claimed in claim 15, wherein the cable has, at the end thereof, a wire end ferrule (63), and wherein the collar (613) of the cable (6) is formed by a protective collar of the wire end ferrule (63).

18. The electric cable connection system as claimed in claim 15, wherein the counter stop edge (242) of the step (24) of the lateral walls (22) extends in each case at right angles to the slide edges (243) thereof.

19. The electric cable connection system as claimed in claim 15, wherein the two lateral actuating arms (122) are configured to be substantially planar and extend parallel to the lateral walls (22) of the busbar (2, 2).

20. The electric cable connection system as claimed in claim 15, wherein the web (123) of the actuator (1) extends at right angles to the slide edges (243) of the lateral walls (22) of the busbar (2, 2).

21. The electric cable connection system as claimed in claim 15, wherein the web (123) has a rounded shape toward the slide edges (243).

22. The electric cable connection system as claimed in claim 15, wherein the actuating arms (122) each have, at the ends thereof, a stop edge (124) with which they abut the respective counter stop edge (242) of a respective one of the two lateral walls (22) in the actuated state of the actuator (1).

23. The electric cable connection system as claimed in claim 15, wherein the web (123) forms at least a part of a projection (13) on the actuator (1) towards the slide edges (243).

24. The electric cable connection system as claimed in claim 15, wherein the collar (613, 613) of the cable (6), at least in the non-actuated state of the actuator (1), dips between the two lateral actuating arms (122) at least in certain regions into a receiving opening (120) of the actuator (1).

25. The electric cable connection system as claimed in claim 15, wherein the clamping leg (33) has a protrusion (335) which, in the actuated state of the actuator (1), is in mechanical contact with the web (123) thereof.

26. The electric cable connection system as claimed in claim 15, wherein the busbar (2, 2) has a coupling portion (25) which is adapted to mechanically fix a plug contact (5) to the busbar (2, 2) and electrically couple the plug contact (5) to the busbar (2, 2).

27. The electric cable connection system as claimed in claim 15, wherein the first cage wall (21) of the cage-shaped busbar (2) has a cage opening (20) or is even fully replaced by an opening (20) of this type, so the cage-shaped busbar (2) is an open cage-shaped busbar (2), and the clamping spring (3), by means of the retaining leg (31) thereof, is at least held or even fastened against the first cage wall (21) from an exterior by pressing, stamping, riveting, screwing, clamping, adhesively bonding and/or latching.

28. The electric cable connection system as claimed in claim 15, wherein the first cage wall (21) and the second cage wall (22) oppose each other in a parallel manner, and wherein the clamping spring (3) supports itself, via the retaining leg (31) thereof, against the first cage wall (21) from an interior.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0047] An exemplary embodiment of the invention is described in greater detail below and is shown in the drawings, in which:

[0048] FIG. 1a shows an actuator;

[0049] FIG. 1b shows a cage-shaped busbar with a plug contact;

[0050] FIGS. 1c, d show a V-shaped clamping spring;

[0051] FIGS. 2a-d show different views of the actuator;

[0052] FIG. 3 shows the busbar with the clamping spring;

[0053] FIGS. 4a-d show different views of an actuation process;

[0054] FIGS. 5a, b show the actuation process, with the contact carrier illustrated;

[0055] FIG. 5c shows a cable;

[0056] FIG. 5d shows a wire end ferrule of the cable;

[0057] FIGS. 6a, b show the actuation of a cable connection system;

[0058] FIGS. 7a, b show a first open busbar with a first clamping spring latched/to be latched thereon;

[0059] FIGS. 7c, d show a second open busbar with a second clamping spring latched/to be latched thereon;

[0060] FIGS. 8a, b show a third open busbar with and without a third clamping spring to be fastened thereto; and

[0061] FIGS. 8c, d show a fourth open busbar with and without a fourth clamping spring to be fastened thereto.

DETAILED DESCRIPTION

[0062] The figures contain schematic illustrations which have been simplified in some cases. In some cases, identical reference signs are used for like elements which may, however, not be identical. Different views of like elements may be scaled differently.

[0063] The figures show a cable connection system and the actuation thereof. The cable connection system has an actuator 1, a cage-shaped busbar 2, 2 with a cable connection side 26, a V-shaped clamping spring 3 and a cable 6, which comprises a collar 613, 613, is to be inserted into the busbar 2, 2 through the cable connection side 26 in the insertion direction and is to be electrically coupled to the busbar 2 by means of the clamping spring 3 and thus connected thereto. Also shown is a plug contact 5, which is electrically and mechanically coupled to the busbar 2, 2 at a coupling portion 25, and a contact carrier 4 which receives the aforementioned arrangement.

[0064] In the drawings, the cable connection side 26 is, in principle, shown at the top. The cable insertion direction extends from top to bottom in the drawings.

[0065] FIG. 1a shows the actuator 1. The actuator 1 has a substantially cuboid-shaped retaining portion 14, with which it can be held in the contact carrier 4. At the cable connection end (shown at the top in the drawing), the actuator 1 has a driving surface 10, for example for applying a tool, for example a slotted screwdriver. The driving surface 10 has a structure which facilitates the application of the slotted screwdriver.

[0066] Adjacent to the retaining portion 14 on the plug side, the actuator 1 has an actuating portion 12 for cooperating with the cage-shaped busbar 2 shown below and the clamping spring 3 described in greater detail below. The actuating portion 12 has two mutually opposing actuating arms 122, which are coupled to each other at the ends thereof by a web 123. The web 123 forms at least part of a projection 13. The actuating arms 122 are configured to be planar. A through-opening, namely a receiving opening 120, remains between the actuating arms 122. In the proximity of the web 123 (at the bottom of the drawing), a portion of this receiving opening 120 continues into the projection 13. Adjacent to the web 123, the actuating arms 122 each have a stop edge 124 which terminates flush with the web 123 in the cable insertion direction, i.e., from top to bottom in the drawing.

[0067] FIG. 1b shows a cage-shaped busbar 2 with a plug contact 5 which is fastened and electrically conductively coupled to the former. In the embodiment shown here, the busbar 2 is a punched-bent part. In the production thereof, the latter can therefore for example be punched from a metal sheet and bent into the desired shape. In other embodiments, the cage-shaped busbar 2 could also be produced in a zinc die-casting process or by milling from a solid, i.e., from a solid material, or the like.

[0068] In the embodiment shown here, the busbar 2 has a cage with two cage walls 21, 23 which oppose each other in a parallel manner, namely a first cage wall 21 and a second cage wall 23, which are coupled to each other by two further walls of the cage, namely two lateral walls 22. The embodiment shown here makes it possible for the clamping spring 3 to support itself against the first cage wall 21 from the interior while pressing against the second cage wall 23 via the clamping leg 33 thereof. As soon as an electrical conductor, for example a core 60 of an electrical cable 6 shown further below, is introduced into the busbar 2 between the second cage wall 23 and the second clamping leg 33 of the clamping spring in the cable insertion direction, this electrical conductor is by the clamping spring by means of the clamping leg

[0069] On the cable insertion side, the two lateral walls 23 each have a step 24, which in each case forms a slide edge 243 extending in the cable insertion direction and a counterstop edge 242 preferably extending at right angles thereto. The busbar 2 has a coupling portion 25 on the plug side for coupling to the plug contact 5.

[0070] FIGS. 1c and 1d show a side view and an oblique plan view of a clamping spring 3. The clamping spring 3 is configured to be substantially V-shaped. It has a retaining leg 31 and a clamping leg 33, which are coupled to each other via a spring bend 32. It is clear from FIG. 1d that retaining means, or more precisely retaining openings, are arranged in the retaining leg 31. The former are used to hold or even fasten the clamping spring against the first cage wall 21.

[0071] At the spring bend 32, the spring is bent by more than 270?, so the two legs 31, 33 form an acute angle to each other. The clamping leg 33 has a protrusion 335 and a contact region 336 adjoining the latter.

[0072] FIGS. 2a-d show the actuator 1 again in different views, namely an oblique plan view, an oblique rear view, a front view and a side view. It is evident in particular from the side view shown in FIG. 2d that the web 123 is merely part of a projection 13, since the receiving opening 120 extends into the projection 13. In another embodiment, however, the web 123 could also form the entire projection 13.

[0073] FIG. 3 shows the cage-shaped busbar 2 with the V-shaped clamping spring 3 held therein. The clamping spring 3 supports itself, via the retaining leg 31 thereof, against the first cage wall 21 from the interior, and simultaneously presses, via the clamping leg 33 thereof, against the second cage wall 23 from the interior. Via the retaining openings 310 of the retaining leg 31 thereof, the clamping spring 3 can be held against the first cage wall 21 from the interior, for example by inwardly directed stamping regions in the first cage wall 21, which prevent the clamping spring from being displaced in or counter to the cable insertion direction.

[0074] In addition, the busbar 2 has a coupling portion 25, via which a plug contact 5 is electrically conductively coupled and mechanically fastened to the busbar 2. The plug contact 5 and the busbar 2 may be manufactured from different electrically conductive materials.

[0075] FIGS. 4a and 4b show three-dimensional and sectional views of the busbar 2 with the clamping spring 3 and the actuator 1 in a non-actuated state. FIGS. 4c and 4d show the actuator 1 and the clamping spring 3 in an actuated state.

[0076] The lateral walls 22 of the busbar 2 each have the said step 24 with the slide edge 243 and the counterstop edge 242.

[0077] From these illustrations it is clear to see that, during actuation of the actuator 1, in which the latter is displaced in the cable insertion direction, i.e., from top to bottom in the drawing, it slides via the web 123 thereof along the slide edges 243 of the busbar 2 until it strikes, via the stop edges 124 thereof, the counterstop edges 242 of the busbar 2, as shown in FIGS. 4c and 4d. In particular, FIG. 1d further shows that at the moment a stationary position is reached, when the kinetic friction between the actuator 1 and the busbar 2 has transitioned to static friction, the web 123 of the actuator 1 is in mechanical contact with the protrusion 335 of the clamping leg 33 of the clamping spring 3. In this case, as a result of the said actuation, the clamping leg 33 is pivoted in the cable insertion direction, compared to the position thereof shown in FIG. 4b.

[0078] As a result of the mechanical contact between the web 123 and the protrusion 335, the actuator 1 is pressed by the clamping spring 3 more strongly in the direction of the cable connection side 26 and, perpendicularly thereto, correspondingly less strongly against the slide edge 243. It is particularly advantageous that this vectorial change in the direction of the action of force takes place at the very moment at which the particularly high static friction to be overcome arises. The vector component causing the said friction, in particular the said static friction, is reduced in the actuated position by the protrusion 335. In return, the vector component which acts counter to the cable insertion direction and exerts a restoring force on the actuator increases. As a result, it is therefore possible for the static friction to be somewhat further reduced, and the force component overcoming the former to be increased in the direction of travel of the actuator 1.

[0079] However, since this aforementioned effect by the said protrusion 335 is also limited, it is further particularly advantageous to minimize the static friction arising between the actuator 1 and the busbar 2, namely the web 123 and the slide edges 243, by other/additional measures. This static friction may be further reduced by minimizing the contact surface between the web 123 of the actuator 1 and the slide edges 243 of the busbar 2. It is firstly therefore already very advantageous that the web 123 extends perpendicularly to the slide edges 243. In addition, it is further advantageous if the web 123 has a rounded shape toward the slide edges 243.

[0080] FIGS. 5a and 5b show a comparable arrangement and a comparable process, wherein it is also shown that the actuator 1 and the busbar 2, and consequently also the clamping spring 3 and the plug contact 5, are received in a contact carrier 4 and held therein.

[0081] For this purpose, the contact carrier has a connection region 42 for receiving the busbar 2, the clamping spring 3 and the actuator 1, and a plug region 45, which is open on the plug side (at the bottom in the drawing), for receiving the plug contact 5 and for plugging this plug contact 5 in, for example, a mating plug connector.

[0082] The actuator 1 is in this case arranged in a recessed manner in an actuation opening 40 of the contact carrier 4 and can be actuated through this actuation opening 40 on the cable connection side, i.e., from the direction of the cable connection side 26, for example with a slotted screwdriver. During the actuation process, the actuator 1 may be guided by means of the contact carrier 4. However, a considerable proportion of the frictional resistance arises between the actuator 1 and the busbar 2, against which the actuator 1 is pressed by the clamping spring.

[0083] In addition, the contact carrier 4 has a connection opening 400, through which a cable 6 for establishing contact with the busbar 2 can be inserted into the busbar 2 in the cable connection direction, i.e., from top to bottom in the drawing.

[0084] FIG. 5c shows an electrical cable 6 and FIG. 5d shows an associated wire end ferrule 63. The cable 6 comprises an electrically conductive core 60 and has a transmission portion 61 and a contact portion 62 at the end thereof to be inserted into the busbar 2. In the transmission portion 61 thereof, the electrical cable 6 has an electrically insulating sheath 610 which surrounds the core 60 in a radial manner. The contact portion 62 of the cable 6 is used to establish electrical contact with the busbar 2 and therefore does not have an electrically insulating sheath 610, so the core 60 of the cable 6 is not sheathed in the contact portion 62. Adjacent to the contact portion 62, the cable 6 has a collar 613, 613 in the transmission portion 61 thereof. The collar 613, 613 consists of an electrically insulating material. In an embodiment, the collar 613 is formed by an end portion of the sheath 610. Alternatively, in another embodiment, the cable may have, at the end thereof, the wire end ferrule 63, which is slid onto the cable end to be inserted and crimped thereto via the crimping region 630 thereof. In this case, the said collar 613 may be part of the wire end ferrule 63. In particular, the collar 613 is in this case what is referred to as a protective collar of the wire end ferrule 63.

[0085] FIG. 6a shows a cable connection system, having the actuator 1, the cage-shaped busbar 2, the V-shaped clamping spring 3 and the cable 6, wherein the actuator 1 is disposed in the non-actuated position thereof. FIG. 6b shows the same arrangement in the actuated state.

[0086] FIGS. 6a and 6b further show how the cable 6, with the collar 613 and the stripped and crimped contact portion 62 thereof, which is thus surrounded by the crimping region 630 of the wire end ferrule 63, is arranged in the busbar 2.

[0087] In both the actuated and non-actuated states, the collar 613 of the cable 6 is arranged on the cable connection side, i.e., above the web 123 of the actuator 1 in the drawing.

[0088] This achieves a particularly compact design for the cable connection system. This effect is further enhanced by the receiving opening 120 of the actuator 1, since the receiving opening 120 is able to partially receive particularly large collars 316, 316 belonging to cables 6 with cores 60 having a relatively large cross-section, thereby creating additional space, i.e., in other words, further improving the compact nature of the design of the cable connection system in relation to the size of the cable cross sections of the cables 6 to be received.

[0089] Forming the web 123 to be at least part of the projection 13 also assists in minimizing the frictional resistance and in particular the static frictional resistance of the actuator 1 against the busbar 2, as already described in detail.

[0090] FIGS. 7a-d and 8a -d show further embodiments of busbars 2 which may likewise be part of the cable connection system. Although they differ from each other, the open busbars are denoted with the reference sign 2 below for reasons of clarity. In the examples shown here, the busbar 2 may be formed in one piece from a metallic material, for example by die casting or by milling from a solid.

[0091] In principle, the busbars 2, 2 shown here in the exemplary embodiment may be formed both from a single material and from a plurality of different, in particular metallic, materials such as zinc alloys and/or copper alloys and/or aluminum alloys and/or sheet metal.

[0092] In these embodiments, the first cage wall 21 of the cage-shaped busbar 2 has a cage opening 20. This has the advantage that the busbar/cage of the busbar 2 is open toward the retaining leg 31 of the clamping spring 3, so the clamping spring 3 can, via the retaining leg 31 thereof, be resiliently pivoted at least slightly out of the cage of the busbar 2. The busbars 2 shown in these illustrations are therefore referred to as open cage-shaped busbars 2.

[0093] In open cage-shaped busbars 2 of this type, the retaining leg 31 of the clamping spring 3 is fastened to the busbar 2 from the exterior, for example by pressing, stamping, riveting, screwing, clamping, adhesively bonding and/or latching and/or a similar fastening method.

[0094] FIGS. 7a and 7b show a first open cage-shaped busbar 2 which has a cage latch 213 and in which at least a part 21 of the cage latch 213 can be interpreted as part of the first cage wall 21 which has the said cage opening 20 above the cage latch 213. A first further clamping spring 3 appropriate therefor also has, on the clamping leg 31 thereof, an additional retaining latch 313 corresponding to the cage latch 213. This latch is particularly stable.

[0095] FIGS. 7c and 7d show a second open cage-shaped busbar 2 in which the cage latch 231 and the retaining latch 313 extend perpendicularly to the cable insertion direction, in contrast to the arrangement shown above. A second further clamping spring 3 appropriate therefor is consequently held via the retaining leg 31 thereof against the first cage wall 21, from the exterior on this occasion.

[0096] FIGS. 8a and 8b show a third open cage-shaped busbar 2, to which a third further clamping spring 3 is fastened by stamping the retaining leg 31 thereof by means of a retaining opening 310 (not denoted here for reasons of clarity) arranged in the retaining leg 31 and a retaining stamping region 214 which is still cylindrical at this point and is subsequently stamped. The third further clamping spring 3 is in this case also subsequently fastened via the retaining leg 31 thereof to the first cage wall 21, albeit from the exterior.

[0097] In contrast, FIGS. 8c and 8d show a fourth open cage-shaped busbar 2, in which a fourth clamping spring 3 appropriate therefor is similarly positioned, via the retaining leg 31 thereof and the retaining opening 310 (not denoted here) located therein, on a retaining pin 214 in FIG. 8d, but this retaining pin 214 is not stamped. Instead, the two lateral walls 22 of the cage-shaped busbar 2 are elongated in the fastening region of the retaining leg 31 of the fourth clamping spring 3 and, depending on the material properties of the busbar, can be more or less easily bent to fix the fourth clamping spring 3 via the retaining leg 31 thereof. Following this bending process, the fourth clamping spring 3 is also fastened via the retaining leg 31 thereof to the first cage wall 21 of the fourth busbar 2 from the exterior.

[0098] Even though different aspects or features of the invention are each shown in combination in the figures, it is apparent to a person skilled in the art, unless otherwise indicated, that the combinations shown and discussed are not the only possible combinations. In particular, corresponding units or combinations of features from different exemplary embodiments can be exchanged with one another.

LIST OF REFERENCE SIGNS

[0099] 1 actuator [0100] 10 driving surface [0101] 12 actuating portion [0102] 120 receiving opening [0103] 122 actuating arms [0104] 123 web [0105] 124 stop edge [0106] 13 projection [0107] 14 retaining portion [0108] 2 cage-shaped busbar [0109] 2 open cage-shaped busbars [0110] 20 cage opening [0111] 21, 21 first cage wall [0112] 213, 213 cage latch [0113] 214 cage stamping portion [0114] 214 retaining pin [0115] 224 clamping tabs [0116] 22 lateral walls [0117] 23 second cage wall [0118] 24 step [0119] 242 counterstop edge [0120] 243 slide edge [0121] 25 coupling portion [0122] 26 coupling side [0123] 3 clamping spring [0124] 3 further (first, second, third, fourth) clamping springs [0125] retaining leg 31 [0126] 310 retaining opening [0127] 313 retaining latch [0128] 32 spring bend [0129] 33 clamping leg [0130] 335 protrusion [0131] 336 contact portion [0132] 4 contact carrier [0133] 40 actuation opening [0134] 400 connection opening [0135] 42 connection region [0136] 45 plug region [0137] 5 plug contact [0138] 6 cable [0139] 60 core [0140] 61 transmission portion [0141] 610 sheath [0142] 613, 613 collar, protective collar [0143] 62 contact portion [0144] 63 wire end ferrule [0145] 630 crimping region