Electrical connector system

• US 8,827,729 B2
• Filed: 04/05/2011
• Issued: 09/09/2014
• Est. Priority Date: 04/09/2010
• Status: Active Grant

• Current Assignee: Aptiv Technologies Limited (BorgWarner Incorporated)
• Original Assignee: Delphi International Operations Luxembourg S.à r.l.
• Inventors: Gunreben, Michael, Pabst, Thomas Bernhard, Schwerin, Thomas
• Primary Examiner(s): LEON MUNOZ, EDWIN A
• Application Number:
  US13/639,555
• Publication Number:
  US 20130078835A1
• Time in Patent Office: 1,253 Days
• Field of Search: 439/188, 439350-354, 439357-358, 439/131, 439/133, 439/137, 439/145, 439/166, 439/152, 439/252, 439/476.1, 439/488, 439/489, 439/491
• US Class Current: 439/188
• CPC Class Codes: B60L 2270/32 of electricity
• CPC Class Codes: B60L 2270/34 of parts
• CPC Class Codes: B60L 3/0069 relating to the isolation, e.g. ground fault or leak current
• CPC Class Codes: B60L 3/04 Cutting off the power supply under fault conditions protective devices and circuit arrangements in general H01H; H02H
• CPC Class Codes: B60L 53/16 Connectors, e.g. plugs or sockets, specially adapted for charging electric vehicles
• CPC Class Codes: H01R 13/44 Means for preventing access to live contacts making use of a switch actuated by engagement of counterpart H01R13/7036
• CPC Class Codes: H01R 13/5202 Sealing means between parts of housing or between housing part and a wall, e.g. sealing rings
• CPC Class Codes: H01R 13/5205 Sealing means between cable and housing, e.g. grommet H01R13/5221 takes precedence
• CPC Class Codes: H01R 13/53 Bases or cases for heavy duty; Bases or cases for high voltage with means for preventing corona or arcing
• CPC Class Codes: H01R 13/6271 Latching means integral with the housing H01R13/6276, H01R13/6277, H01R13/6278 take precedence
• CPC Class Codes: H01R 13/639 Additional means for holding or locking coupling parts together, after engagement, e.g. separate keylock, retainer strap
• CPC Class Codes: H01R 13/658 High frequency shielding arrangements, e.g. against EMI [Electro-Magnetic Interference] or EMP [Electro-Magnetic Pulse] coaxial coupling devices specially adapted for high frequency H01R24/40; for flat or ribbon cable connectors H01R12/774; for coaxial cable H01R9/05
• CPC Class Codes: H01R 13/6593 the shield being composed of different pieces
• CPC Class Codes: H01R 13/70 with built-in switch
• CPC Class Codes: H01R 13/701 the switch being actuated by an accessory, e.g. cover, locking member
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 10/7072 Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
• CPC Class Codes: Y02T 90/12 Electric charging stations
• CPC Class Codes: Y02T 90/14 Plug-in electric vehicles

Abstract

The present invention relates to an electrical connector system. The electrical connector system includes a first connector to be mated to a corresponding counter connector and it is further adapted to be connected to a signal circuit for activating an electrical power source upon switching. As a safety feature, the connector system further includes a connector position assurance (CPA) member assigned to the first connector, which is movable, whereby an end position is not reachable if the first connector is incorrectly mated to the counter connector. The CPA member is adapted to interact with the signal circuit if placed in said end position so that it activates of the electrical power source.

Claims

1. An electrical connector system, comprising:

a first connector;

a second connector configured to be mated to the first connector;

a latching means configured to secure the first connector to the second connector when the first connector is completely mated with the second connector; and

a connector position assurance (CPA) member, said CPA member being movable from a start position to an end position, wherein said latching means prevents movement of the CPA member to the end position when the first connector is not completely mated to the second connector and the CPA member prevents the latching means from releasing the first connector when the CPA member is in the end position and wherein when moved to said end position, the CPA member activates a signal circuit to enable an electrical power source.

2. The electrical connector system according to claim 1, wherein the signal circuit comprises a switching device and wherein said CPA member contacts the switching device when moved to the end position.

3. The electrical connector system according to claim 2, wherein the switching device comprises at least one of the group consisting of:

a micro switch;

two electrical contacts integrated in the signal circuit, closing the signal circuit when in electrical contact with each other; and

a variable resistor.

4. The electrical connector system according to claim 1, wherein the signal circuit comprises two electrical contacts and the CPA member comprises a shorting clip configured to connect the two electrical contacts when the CPA member is moved to the end position, thereby activating the signal circuit.

5. The electrical connector system according to claim 1, comprising an electromagnetic shielding element and an electromagnetically shielded conductor, the electromagnetic shielding element establishing shielding continuity for the electromagnetically shielded conductor throughout the electrical connector system when the first connector is correctly mated to the second connector.

6. The electrical connector system according to claim 5, wherein the electromagnetic shielding element is characterized as an electromagnetic shielding sleeve and wherein the CPA member and the signal circuit are disposed outside of the electromagnetic shielding element.

7. The electrical connector system according to claim 6, wherein the electromagnetic shielding element is electrically connected to the electromagnetically shielded conductor without any separate contact spring members.

8. The electrical connector system according to claim 5, wherein the electromagnetic shielding element provides shielding over the electrical connector system of more than 70 dB in the range of 10 kHz to 5 MHz and more than 65 dB in the range of 5 MHz to 500 MHz when the first connector is correctly mated to the second connector.

9. The electrical connector system according to claim 5, comprising sealing elements forming a sealed area between the first connector and the second connector when the first connector and the second connector are mated, wherein the electromagnetic shielding element is completely located within the sealed area.

10. The electrical connector system according to claim 1, wherein the electrical connector system is configured to transmit a power of more than 50 kW.

11. The electrical connector system according to claim 1, further comprising the signal circuit.