ELECTRICAL PLUG CONNECTOR FOR A BUSBAR

Abstract

The present invention relates to an electrical plug connector for an electrical connection system. The electrical plug connector comprises a plug connector housing comprising a housing body and a busbar portion. The busbar portion is at least partially accommodated in the plug connector housing. The busbar portion includes a busbar conductor, and a busbar end which is integrally formed with the busbar conductor. The busbar end includes a connection portion that is configured for being plugged to a mating connector to establish an electrical connection. The busbar end further includes a retention means which is configured to engage with a corresponding retention means to receive pull forces being imposed on the busbar portion in a direction opposite to a mating direction. The plug connector housing has a corresponding retention means that engages with the retention means when the busbar portion is at least partially accommodated in the plug connector housing.

Claims

1. An electrical plug connector for an electrical connection system, particularly for a busbar of an electrical vehicle, the electrical plug connector comprising: a plug connector housing including a housing body; and a busbar portion, wherein the busbar portion is at least partially accommodated in the plug connector housing, wherein the busbar portion includes: a busbar conductor, and a busbar end which is integrally formed with the busbar conductor, wherein the busbar end includes a connection portion, the connection portion being configured for being plugged to a mating connector to establish an electrical connection, wherein the busbar end further includes a retention means, which is configured to engage with a corresponding retention means to receive pull forces being imposed on the busbar portion in a direction opposite to a mating direction, and wherein the plug connector housing includes a corresponding retention means, that engages with the retention means, when the busbar portion is at least partially accommodated in the plug connector housing.

2. The plug connector according to claim 1, wherein the plug connector housing further comprises a busbar retainer, wherein the corresponding retention means is provided at the busbar retainer, and wherein the busbar retainer may be fixedly accommodated at the housing body.

3. The plug connector according to claim 2, wherein the busbar retainer comprises at least two parts.

4. The plug connector according to claim 3, wherein the two parts are further connected by means of a snap connection.

5. The plug connector according to claim 1, wherein the retention means includes a recess and/or a protrusion and wherein the retention means optionally encircles the busbar conductor.

6. The plug connector according to claim 5, wherein the retention means is further formed by deformation of the busbar conductor or by machining the busbar conductor.

7. The plug connector according to claim 1, wherein the corresponding retention means includes a recess and/or a protrusion and wherein the corresponding retention means preferably has a substantially annular shape.

8. The plug connector according to claim 1, wherein the plug connector housing comprises a tip protection means, wherein the tip protection means may be configured to avoid an unintended touching of a tip portion of the connection portion, and wherein the tip protection means may be fixedly accommodated at the housing body.

9. The plug connector according to claim 1, wherein the plug connector housing comprises a sealing portion, wherein the sealing portion may seal a space between the housing body and the busbar portion, and wherein the sealing portion may comprise a seal.

10. The plug connector according to claim 9, wherein the sealing portion further comprises a sealing retainer and/or a sealing cap.

11. The plug connector according to claim 1, wherein the plug connector housing comprises a mating lever that is arranged pivotable relative to the housing body between an alignment position and a mating position, wherein, the mating lever allows the mating connector to be aligned with the housing body in the alignment position, and the mating lever couples the housing body with the mating connector in a mated configuration in the mating position, and wherein the mating lever is configured to be engageable with the mating connector, in order to move the plug connector along a mating direction relative to the mating connector into the mated configuration when being pivoted from the alignment position to the mating position.

12. The plug connector according to claim 1, wherein the plug connector housing has a coupling means for being coupled to a further plug connector.

13. A system, comprising: a first electrical plug connector according to claim 12; and a second electrical plug connector according to claim 12, wherein the first plug connector is coupled to the second plug connector, wherein preferably one of the plug connectors houses a positive electrical phase and the other one of the plug connectors houses a corresponding negative electrical phase.

14. A mating connector for an electrical connection system, comprising: a mating connector housing; and a busbar receiving portion, wherein the busbar receiving portion is at least partially accommodated in the mating connector housing, wherein the busbar receiving portion is configured to mate with a connection portion of a busbar end which is integrally formed with a busbar conductor, wherein the busbar end includes a connection portion, the connection portion being configured for being plugged to a mating connector to establish an electrical connection, wherein the busbar end further comprises a retention means, which is configured to engage with a corresponding retention means to receive pull forces being imposed on the busbar portion in a direction opposite to a mating direction, and wherein the plug connector housing comprises a corresponding retention means, that engages with the retention means, when the busbar portion is at least partially accommodated in the plug connector housing.

15. The mating connector according to claim 14, wherein the busbar receiving portion has a mounting end, for being mounted on a substrate.

16. An electrical connection system, comprising: a plug connector according to claim 1; and a mating connector for establishing an electrical connection to the plug connector, the mating connector comprising: a mating connector housing; and a busbar receiving portion, wherein the busbar receiving portion is at least partially accommodated in the mating connector housing, wherein the busbar receiving portion is configured to mate with a connection portion of a busbar end which is integrally formed with a busbar conductor, wherein the busbar end includes a connection portion, the connection portion being configured for being plugged to a mating connector to establish an electrical connection, wherein the busbar end further comprises a retention means, which is configured to engage with a corresponding retention means to receive pull forces being imposed on the busbar portion in a direction opposite to a mating direction, and wherein the plug connector housing comprises a corresponding retention means, that engages with the retention means, when the busbar portion is at least partially accommodated in the plug connector housing.

17. A method for assembling a busbar, particularly the busbar of an electrical vehicle, comprsing: a. providing a mating connector comprising: a mating connector housing; and a busbar receiving portion, wherein the busbar receiving portion is at least partially accommodated in the mating connector housing, wherein the busbar receiving portion is configured to mate with a connection portion of a busbar end which is integrally formed with a busbar conductor, wherein the busbar end includes a connection portion, the connection portion being configured for being plugged to a mating connector to establish an electrical connection, wherein the busbar end further comprises a retention means, which is configured to engage with a corresponding retention means to receive pull forces being imposed on the busbar portion in a direction opposite to a mating direction, and wherein the plug connector housing comprises a corresponding retention means, that engages with the retention means, when the busbar portion is at least partially accommodated in the plug connector housing; b. providing a busbar which includes a plug connector,comprising: a plug connector housing comprising a housing body; and a busbar portion, wherein the busbar portion is at least partially accommodated in the plug connector housing, wherein the busbar portion comprises: a busbar conductor, and a busbar end which is integrally formed with the busbar conductor, wherein the busbar end includes a connection portion, the connection portion being configured for being plugged to a mating connector to establish an electrical connection, wherein the busbar end further comprises a retention means, which is configured to engage with a corresponding retention means to receive pull forces being imposed on the busbar portion in a direction opposite to a mating direction, and wherein the plug connector housing comprises a corresponding retention means, that engages with the retention means, when the busbar portion is at least partially accommodated in the plug connector housing, and c. mating the mating connector and the plug connector.

18. A busbar which comprises a busbar conductor and at least two busbar ends, wherein one of the at least two busbar ends is provided with an electrical plug connector according to claim 1.

19. A wiring harness, in particular for an electrical vehicle, wherein the wiring harness comprises a busbar according to claim 18.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0065] The present invention is now described, by way of example with reference to the accompanying drawings, in which:

[0066] FIG. 1 is a schematic view of a busbar portion according to an embodiment of the present disclosure;

[0067] FIG. 2A is an exploded view of an exemplary electrical plug connector according to the present disclosure;

[0068] FIG. 2B is an exploded view of an exemplary electrical connection system according to the present disclosure;

[0069] FIG. 3 is a schematic view of a system including a first electrical plug connector and a second electrical plug connector according to the present disclosure;

[0070] FIG. 4 is a cross-section view of an exemplary electrical connection system according to the present disclosure;

[0071] FIG. 5 is a cross-section view of an exemplary electrical connection system according to the present disclosure, and

[0072] FIG. 6 illustrates a method for assembling a busbar.

DETAILED DESCRIPTION

[0073] FIG. 1 is a schematic view of a busbar portion 1 according to an embodiment of the present disclosure. The busbar portion 1 includes a busbar conductor 12, and a busbar end 15 which is integrally formed with the busbar conductor 12. In the embodiment of FIG. 1, “integrally formed” means that a material of the busbar conductor 12 continuously transitions to the busbar end 15. Thus, no material boundary exists. Hence, the busbar end 15 may not be explicitly differentiated from the busbar conductor 12. Accordingly, the electric resistance is reduced. The busbar end 15 includes a rectangular cross section. Further, the busbar conductor 12 has the shape of a flat beam.

[0074] The busbar end 15, as depicted in FIG. 1, includes a connection portion 16. The connection portion 16 is configured for being plugged to a mating connector to establish an electrical connection. Moreover, the busbar end 15 further includes a plated area 11, in which a plating material is directly plated on the busbar conductor 12. Thereby, the plated area 11 partially corresponds to the connection portion 16. The plated area 11 encircles the busbar end 15.

[0075] A tip portion 18 of the connection portion 16 is not plated, as illustrated in FIG. 1. Thereby, each edge of the tip portion 18 which is perpendicular to the mating direction A is chamfered. Thus, the tip portion has a tapered shape. The chamfered edges and the tapered shape may allow that the connection portion 16 of the busbar end 15 may be easily inserted into the mating connector.

[0076] As shown by FIG. 1, the busbar end 15 further includes two retention means 14a, 14b, which are configured to engage with a corresponding retention means to receive pull forces being imposed on the busbar portion 1 in a direction opposite to a mating direction A. The two retention means 14a, 14b are recesses. The recesses 14a, 14b may have been formed by material deformation. The deformation may have been conducted by pressing and/or squeezing. Moreover, the recesses 14a, 14b may have also been formed by cutting, milling, machining and/or drilling.

[0077] Moreover, the busbar conductor 12 of the embodiment of FIG. 1 is partially surrounded by an isolation 10. Thereby, the isolation 10 is removed from the busbar end 15.

[0078] FIG. 2A is an exploded view of an exemplary electrical plug connector 100 according to an embodiment of the present disclosure. In the following the assembled state of the electrical plug connector 100 is described.

[0079] The plug connector 100 as depicted in FIG. 2A includes a plug connector housing 110. The plug connector housing includes a housing body 111. Thereby the housing body 111 defines an inner volume. The shape of the inner volume corresponds to a rectangular through hole with rounded edges.

[0080] Moreover, the plug connector 100 includes a busbar portion 1 according to the embodiment as depicted in FIG. 1. The busbar portion 1 is partially accommodated in the plug connector housing 110.

[0081] The plug connector housing 110 of FIG. 2A includes two corresponding retention means 120a, 120b, that engage with two retention means 14a, 14b of the busbar portion 1. In particular, the plug connector housing 110 includes a busbar retainer 130. The two corresponding retention means 120a, 120b are provided at the busbar retainer 130. When assembled, the busbar retainer 130 is fixedly accommodated inside the housing body 111. In the embodiment shown, the corresponding retention means 120a, 120b are integrally formed with the busbar retainer 130, particularly with part 131 of the busbar retainer 130.

[0082] Further, the busbar retainer 130 includes two parts 131, 132. These two parts 131, 132 are connected by means of a snap connection, thereby securing the busbar portion 1 within the busbar retainer 130. One part 131 of the busbar retainer 130 includes the two corresponding retention means 120a, 120b, whereas the other part 132 fixedly attaches the busbar retainer 130 to the busbar portion 1. The busbar retainer 130 retains the busbar portion 1 within the housing body 111.

[0083] The two corresponding retention means 120a, 120b are formed as protrusions. The two corresponding retention means 120a, 120b may be formed by casting and/or injection molding the part 131 of the busbar retainer 130.

[0084] The plug connector housing 110 includes a tip protection means 140. The tip protection means 140 avoids a contact with a tip portion 18 of a connection portion 16 of the busbar portion 1. Thereby the tip protection means 140 is fixedly accommodated at the housing body 111. The tip protection means 140 particularly ensures that an unintended touching, such as a finger contact with the tip portion 18 is avoided. Hence, security can be improved. Further, the tip protection means 140 prevents the tip portion 18 of a connection portion 16 of the busbar portion 1 from being damaged during assembly and mating.

[0085] The plug connector housing 110 includes a sealing portion 150. The sealing portion 150 seals a space between the housing body 111 and the busbar portion 1. In particular, the sealing portion 150 seals an interieur space of the housing body 111 against humidity, dust and/or other elements. Further, the sealing portion 150 fixates the busbar retainer 130 and the tip protection means 140 within the housing body 111.

[0086] The sealing portion 150 includes a seal 151. The seal 151 is configured to be in sealed contact with the busbar portion 1 and the housing body 111.

[0087] The sealing portion 150 further includes a seal retainer 152 and a sealing cap 153. The seal retainer 152 fixates the seal 151 inside the housing body 111 and on the busbar portion 1. Further, the sealing cap 153 secures the seal 151 and the seal retainer 152 within the housing body 111. Further, the sealing cap secures the tip protection means 140 and the busbar retainer 130 within the housing body 111. With providing the sealing portion, the plug connector 100 is suited for rough environments and prevents the electrical connection from being distorted, e.g., by moisture, dust and/or the like.

[0088] The plug connector housing 110 includes a mating lever 160 that is arranged pivotable relative to the housing body 111 between an alignment position and a mating position. The mating lever facilitates mating of the plug connector 100 with a corresponding mating connector.

[0089] Further, the plug connector housing further includes a connector position assurance member 112 that is arranged moveable relative to the housing body 111 so as to be moveable into a locked position. Particularly, the connector position assurance member 112 is supported by the housing body 111 so as to be axially slidable. In the locked position, the connector position assurance member 112 locks the mating lever 160 in the mating position. Hence, in case the mating lever 160 is in its mating position and the connector position assurance member 112 is in the locked position a proper electrical connection is established.

[0090] FIG. 2B is a partially exploded view of an exemplary electrical connection system 300 according to an embodiment of the present disclosure. The system 300 includes a plug connector 100 and a mating connector 200 for establishing an electrical connection to the plug connector 100. In the following the assembled state of the electrical connection system 300 is described.

[0091] The plug connector 100 of the system 300 shown in FIG. 2B is depicted in FIG. 2A in an exploded view and described above.

[0092] The mating connector 200 being depicted in an exploded view in FIG. 2B includes a mating connector housing 210 and a busbar receiving portion 220. When assembled, the busbar receiving portion 220 can be at least partially accommodated in the mating connector housing 210. The busbar receiving portion 220 is configured to mate with a connection portion 16 of a busbar end 15, as described above, to establish an electrical connection. Hence, on busbar-side no terminal is required. The busbar receiving portion 220 may include multiple (at least two) contact fingers. In the depicted embodiment the busbar receiving portion 220 includes six contact fingers. Thereby each contact finger is arranged opposite to another contact finger. The stability of the electrical contact can thus be improved.

[0093] The busbar receiving portion 220 has a mounting end 225, for being mounted on a substrate. The substrate may be a battery terminal, a motor terminal, a charging socket and/or a cable. Thereby, the busbar receiving portion 220 as shown is configured for being mounted on a substrate by means of screwing. The mounting end 225 may have different configurations, such as a crimping end, a soldering end, a welding end and/or the like.

[0094] FIG. 3 is a schematic view of a system 500 including a first electrical plug connector 100 and a second electrical plug connector 400. The first plug connector 100 corresponds to the embodiment of FIG. 2A. The second plug connector 400 also corresponds to the embodiment of FIG. 2A but without a mating lever. The first plug connector 100 is coupled to the second plug connector 400. Preferably one of the plug connectors houses a positive phase and the other one of the plug connectors houses a corresponding negative phase. Preferably, both phases are direct current (DC) phases.

[0095] FIG. 4 is a cut view of an exemplary electrical connection system 300 according to the present disclosure. The system 300 includes a plug connector 100 and a mating connector 200 establishing an electrical connection. The plug connector 100 and the mating connector 200 are mated.

[0096] The plug connector 100 includes a plug connector housing 110 which includes a housing body 111. Moreover, the plug connector 100 includes a busbar portion 1 according to the embodiment of FIG. 1. The busbar portion 1 is partially accommodated in the plug connector housing 110.

[0097] The busbar portion 1 includes a busbar conductor 12, and a busbar end 15 which is integrally formed with the busbar conductor 12. The busbar end 15 includes a connection portion 16, the connection portion 16 being plugged to the mating connector 200 and establishing an electrical connection. The busbar end 15 further includes two retention means 14a, 14b, which engage with two corresponding retention means 120a, 120b to receive pull forces being imposed on the busbar portion 1 in a direction opposite to a mating direction A.

[0098] The plug connector housing 110 includes two corresponding retention means 120a, 120b, that engage with the two retention means 14a, 14b. In particular, the plug connector housing 110 includes a busbar retainer 130. The two corresponding retention means 120a, 120b are provided at the busbar retainer 130. Further particularly, the two corresponding retention means 120a, 120b are provided at the first part of the busbar retainer 130. The busbar retainer 130 is fixedly accommodated inside the housing body 111. The retention means 14a, 14b are formed as recesses. The two retention means 14a, 14b are relatively offset to each other in the mating direction A. Thus, a reduction of an area of a cross section perpendicular to the mating direction A of the busbar conductor 12 can be reduced. The corresponding retention means 120a, 120b are protrusions.

[0099] The plug connector housing 110 includes a tip protection means 140. The tip protection means 140 particularly serves to avoid a contact, e.g., of a finger, with a tip portion 18 of the connection portion 16 when the plug connector 100 and the mating connector 200 are not mated.

[0100] The plug connector housing 110 includes a sealing portion 150. The sealing portion 150 seals a space between the housing body 111 and the busbar portion 1. Further, the sealing portion 150 fixates the busbar retainer 130 and the tip protection means 140 within the housing body 111.

[0101] The sealing portion 150 includes a seal 151. The seal 151 is in sealed contact with the busbar portion 1 and the housing body 111.

[0102] The sealing portion 150 further includes a seal retainer 152 and a sealing cap 153. The seal retainer 152 fixates the seal 151 inside the housing body 111 and on the busbar portion 1. Further, the sealing cap 153 secures the seal 151 and the seal retainer 152 within the housing body 111. Even further, the sealing cap 153 secures the tip protection means 140 and the busbar retainer 130 within the housing body 111. The sealing cap 153 engages with the housing body 111 by means of a snap connection.

[0103] The mating connector 200 includes a mating connector housing 210 and a busbar receiving portion 220. The busbar receiving portion 220 is partially accommodated in the mating connector housing 210. The busbar receiving portion 220 is mated with a connection portion 16 of a busbar end 15 and establishes an electrical connection. The busbar receiving portion 220 has a mounting end 225, for being mounted on a substrate. The mounting end 225 includes a through hole. Thus, the mounting end 225 may be screwed on a substrate.

[0104] FIG. 5 is a further cut view of the exemplary electrical connection system 300 depicted in FIG. 4. As above mentioned, the system 300 includes a plug connector 100 and a mating connector 200 establishing an electrical connection. The plug connector 100 and the mating connector 200 are mated.

[0105] The plug connector 100 includes a plug connector housing 110 which includes a housing body 111. Moreover, as depicted in FIG. 4 the plug connector 100 of FIG. 5 includes a busbar portion 1 according to the embodiment of FIG. 1. Thereby the cut view of FIG. 5 is perpendicular to the cut view of FIG. 4.

[0106] As further shown in FIG. 5, the busbar receiving portion 220 of the mating connector 200 is at least partially accommodated in the mating connector housing 210. The busbar receiving portion 220 mates with a connection portion 16 of a busbar end 15 to establish an electrical connection. Particularly, the contact fingers of the busbar receiving portion, each contacts the connection portion 16 of the busbar end 15.

[0107] FIG. 6 depicts a method 1000 for assembling a busbar. The method includes the steps of providing 1010 a mating connector 200; (b) providing 1020 a busbar which includes a plug connector 100, and (c) mating 1030 the mating connector 200 and the plug connector 100.

[0108] While this invention has been described in terms of the preferred embodiments thereof, it is not intended to be so limited, but rather only to the extent set forth in the claims that follow. 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 configure 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 prototypical embodiments.

[0109] 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.

[0110] 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.

[0111] 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.

[0112] 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.

[0113] 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.

[0114] 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.