Electrical Connector System

• US 20130078835A1
• Filed: 04/05/2011
• Published: 03/28/2013
• Est. Priority Date: 04/09/2010
• Status: Active Grant

• Current Assignee: Aptiv Technologies Limited (Aptiv PLC)
• Original Assignee: FCI Automotive Holding
• Inventors: Gunreben, Michael, Pabst, Thomas Bernhard, Schwerin, Thomas
• Granted Patent: US 8,827,729 B2
• Time in Patent Office: Days
• 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. Electrical connector system in particular for high power applications involving an electrical power of at least 1.5 kW, the electrical connector system comprising a first connector to be mated to a corresponding counter connector, the electrical connector system further being adapted to be connected to a designated signal circuit for activating an electrical power source upon switching, characterized in that

the electrical connector system further comprises a connector position assurance (CPA) member assigned to the first connector, this CPA member being movable, whereby an end position is not reachable if the first connector is incorrectly mated to the counter connector, whereby the CPA member interacts with the signal circuit if placed in said end position to activate the electrical power source.

2. Electrical connector system according to claim 1, comprising a switching device adapted to switch the signal circuit, the CPA member being adapted to interact physically with this switching device.

3. Electrical connector system according to claim 2, wherein the switching device comprises one or more of the following:

a micro switch;

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

a variable resistor.

4. Electrical connector system according to claim 1, wherein the signal circuit comprises two electrical contacts and the CPA member comprises a shorting clip adapted to connect the two electrical contacts, thereby turning on the signal circuit.

5. Electrical connector system according to claim 1, comprising at least one electromagnetic shielding element and at least one electromagnetically shielded conductor, the at least one electromagnetic shielding element being adapted to establish a shielding continuity for the at least one electromagnetically shielded conductor throughout the electrical connector system in assembled condition.

6. Electrical connector system according to claim 5, wherein the at least one electromagnetic shielding element is realized essentially in form of a sleeve, the CPA member and the signal circuit being arranged outside of the at least one electromagnetic shielding sleeve.

7. Electrical connector system according to claim 6, wherein the at least one electromagnetic shielding sleeve is adapted to be electrically connected to the shielding of the at least one electromagnetically shielded conductor without the need for any separate contact spring members.

8. Electrical connector system according to claim 5, wherein the at least one electromagnetic shielding element provides a shielding continuity adapted to provide a shielding over the electrical connector system in assembled condition of more than 40 dB, preferably of more than 55 dB, most preferably of more than 70 dB in the range of 10 kHz-5 MHz;

and of more than 40 dB, preferably of more than 55 dB, most preferably of more than 65 dB in the range of 5 MHz-500 MHz.

9. Electrical connector system according to claim 5, comprising sealing elements adapted to seal the electrical connector system against moisture, the at least one electromagnetic shielding element being completely located in the sealed area of the electrical connector system when the first connector and the counter-connector are mated.

10. Electrical connector system according to claim 1, adapted to transmit currents of more than 10 A, preferably more than 25 A, most preferably more than 50 A and/or to transmit a power of more than 1.5 kW, preferably more than 10 kW, preferably more than 20 kW, yet more preferably more than 30 kW, even more preferably more than 40 kW and most preferred more than 50 kW.

11. Electrical connector system for high power applications according to claim 1, the system further comprising the counter connector and the signal circuit.