Angled connector and method of assembling an angled connector

An angled connector includes a connector housing, a terminal support held by the connector housing, and a first terminal held in the terminal support. The connector housing has a first terminal passage and a second terminal passage extending at an angle to the first terminal passage. The first terminal passage and the second terminal passage intersect one another in an intersection region. The terminal support is slidable relative to the connector housing along the first terminal passage from a first position to a second position. The first terminal at least partially extends into the first terminal passage. The first terminal is closer to the second terminal passage in the second position than in the first position, and the first terminal is at least partially arranged in the intersection region in the second position.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of the filing date under 35 U.S.C. § 119(a)-(d) of European Patent Application No. 20194283, filed on Sep. 3, 2020.

FIELD OF THE INVENTION

The present invention relates to a connector and, more particularly, to an angled connector.

BACKGROUND

Angled connectors are commonly used for detachable connections of electrical components for allowing, in the coupled state, the transmission of current and/or electrical signals. Since angled connectors allow a change of the plugging direction, they are particularly preferred in applications with tight space constraints.

However, the installation of the angled connectors has proven to be cumbersome. For example, the angled connector may comprise two housing shells, each carrying a respective terminal, wherein the two housing shells may be mounted to one another. The connection of the two housing shells needs to be sealed with a watertight sealing, which is complicated and prone to errors. Moreover, additional costs are incurred for the manufacture, transport and assembly of a multipart housing. Furthermore, a customer or operator is usually required to install the second terminal, for example a cable end terminal, on site. The first terminal, however, may be different to the second terminal; it may be an interface terminal. The customer or operator usually does not possess the necessary equipment for processing and installing the interface terminal, such as stamping equipment.

SUMMARY

An angled connector includes a connector housing, a terminal support held by the connector housing, and a first terminal held in the terminal support. The connector housing has a first terminal passage and a second terminal passage extending at an angle to the first terminal passage. The first terminal passage and the second terminal passage intersect one another in an intersection region. The terminal support is slidable relative to the connector housing along the first terminal passage from a first position to a second position. The first terminal at least partially extends into the first terminal passage. The first terminal is closer to the second terminal passage in the second position than in the first position, and the first terminal is at least partially arranged in the intersection region in the second position.

DETAILED DESCRIPTION OF THE EMBODIMENT(S)

In the following, the exemplary embodiments of the angled connector, according to the invention, are explained in greater detail with reference to the accompanying drawings.

In the figures, the same reference numerals are used for elements which correspond to one another in terms of their function and/or structure.

According to the description of the various aspects and embodiments, elements shown in the drawings can be omitted if the technical effects of these elements are not required for a particular application, and vice versa: i.e. elements that are not shown in the figures but are described herein can be added if the technical effect of those particular elements is advantageous in a specific application.

An angled connector1according to an embodiment is shown inFIG.1. The angled connector1comprises a connector housing2having a first terminal passage4and a second terminal passage6extending at an angle, in this case essentially perpendicular to the first terminal passage4, the first terminal passage4and the second terminal passage6intersecting one another in an intersection region8. The first terminal passage4may have a hollow, tube-like shape.

The first terminal passage4may extend along a longitudinal axis L being arranged at an angle, particularly essentially perpendicular, to the longitudinal axis L of the second terminal passage6, whereby the longitudinal axes L of the respective passages may intersect one another in the intersection region8. In an embodiment, the angled connector1may be an elbow connector, such as a 90° angled connector, wherein a longitudinal axis L of the first terminal passage4may be arranged at about 90° angle to the longitudinal axis L of the second terminal passage6. However, other embodiments, such as 30° or 45° angled connectors, may also be provided.

The angled connector1further comprises a first terminal10, the first terminal10being held in a terminal support12and at least partially extending into the first terminal passage4, as shown inFIG.1. The terminal support12is held slidable relative to the connector housing2along the first terminal passage4, essentially parallel to the longitudinal axis L of the first terminal passage4, from a first, pre-mount, position P, as shown inFIG.1, to a second, connection position C, as shown inFIG.5. In the second position C, the first terminal10is arranged closer to the second terminal passage6than in the first position P, whereby in the second position C, the first terminal10is at least partially arranged in the intersection region8.

In an embodiment, the connector housing2, particularly the parts comprising the respective sections, may be formed as a monolithic component14or a unitary housing. Therefore, the passages4,6may form a continuous through channel of the housing2and no cumbersome sealing of two composite housing parts, each forming a part of a passage, is necessary.

The connector housing2, as shown inFIG.1, may have a housing sleeve16surrounding the first terminal passage4, the housing sleeve16being radially spaced apart from the first terminal passage4. Thus, a sealing compartment18may be formed between an outer surface20of a wall22of the first terminal passage4. The wall22may particularly be tube shaped and surround at least partially the first terminal passage4. A sealing ring24may be positioned in the sealing compartment18, fitting around the outer surface20of the wall22allowing for a sealed connection between the angled connector1and a complementary connector, which compresses the sealing wing24between an inner surface and the outer surface20of the wall22.

As shown inFIG.1, the intersection region8may form respective distal end sections26of the respective passages4,6. Thus, the first terminal passage4and the second terminal passage6together, form an essentially elbow shaped through channel.

The first terminal10may particularly be an interface terminal28, as shown inFIG.1, for mating with a complementary terminal of the complementary connector. Thus, the angled connector1may be adapted as a plug connector. The interface terminal28may comprise an interface end30facing away from the second terminal passage6and/or the intersection region8. A conductor32of the first terminal4may at least partially be surrounded by an electromagnetic shielding34. An electric insulation36may be provided between the conductor32and the shielding34. The conductor32may be a central conductor and the shielding34may be arranged coaxially to the central conductor32. At a connection end38of the first terminal10opposite the interface end30facing towards the second terminal passage6and/or the intersection region8, the conductor32may be at least partially bare for connecting to a second terminal. Therefore, the shielding34and/or an insulation does not interfere in connecting the first terminal10to the second terminal80.

In an embodiment, the interface end30of the first terminal10may be held by the terminal support12. The terminal support12may particularly extend over less than half of the first terminal10, the half being opposite the second terminal passage6, in order to keep a weight of the angled connector1to a minimum and safe material costs. In other words, the terminal support12may extend over less than half of the first terminal10starting from the interface end30.

The terminal support12may be adapted to hold only a tip of the first terminal10, e.g. the interface end30of the first terminal10, and at least partly be arranged outside of the first terminal passage4at least in one of the first and second position P, C, particularly in both positions. Thus, the terminal support12may be easily accessed, allowing a convenient actuation of the terminal support12for inducing movement between the first and second position.

The terminal support12of the first embodiment is further explained in detail with reference toFIGS.1,2and3. The terminal support12may be formed of an electrical insulating material, such as an electrical insulating resin, for example by an injection molding process. Hence, the operator may safely handle the terminal support12without risking an electric shock. The first terminal10and the terminal support12may be separate parts which are detachable from one another, so that the first terminal10and the terminal support12may be formed in different production steps and replaced independently from one another if one part fails or is damaged.

The interface end30of the first terminal10may be at least partially supported by a support collar40, shown inFIGS.1-3, stabilizing the first terminal10within the terminal support12, and preventing accidental falling off the first terminal10due to stress, such as vibrational stress. The support collar40may at least partially fit tightly on a radial outer surface of the first terminal10and extend into the first terminal passage4. Various columns42may form the support collar40, the columns42extending from a front face44of the terminal support12essentially parallel to the longitudinal axis L of the first terminal passage4towards the second terminal passage6, the front face44being arranged at a distal end of the terminal support12, distal to the second terminal passage6.

The columns42may be spaced apart from one another in a circumferential direction, as shown inFIGS.2and3. In this exemplary embodiment, one column42is formed as a securing latch46for securing the relative position of the first terminal10and the terminal support12in at least one direction essentially parallel to the longitudinal axis L of the first terminal passage4. In an embodiment, the securing latch46forms a form lock with the first terminal10, such that pulling the first terminal10relative to the terminal support12towards the second terminal passage6may be prevented. For this, the securing latch46may comprise a radially inward protruding shoulder48at its free end distal to the front face44. The shoulder48may engage a recess50of the first terminal10, as shown inFIG.1, such that an engagement surface52of the shoulder48facing away from the second terminal passage6abuts a counter engagement surface54of the first terminal10facing towards the second terminal passage6. The securing latch46creates a form lock between the first terminal10and the securing latch46, preventing relative movement of the first terminal10and the terminal support12in at least one direction essentially parallel to the longitudinal axis L of the first terminal10.

The securing latch46may be elastically deflectable and may, in an embodiment, be more flexible than the remainder of the support collar40. For this, the length of the securing latch46in a direction essentially parallel to the longitudinal axis L of the first terminal passage4may be larger than the remainder of the support collar40. Particularly, the free end comprising of or consisting of the radially inward protruding shoulder48may extend beyond the remainder of the support collar40towards the second terminal passage6. This may lead to an extension of the lever arm of the securing latch46, increasing the flexibility of the securing latch46. To further increase the flexibility of the securing latch46, the securing latch46may extend in the circumferential direction along less than a 40° arc, and in an embodiment less than a 30° arc. Hence, the first terminal10may be easily mounted to the support collar40by deflecting the securing latch46radially outwardly. The remainder of the support collar40may be rather rigid compared to the at least one securing latch46.

When the terminal support12is mounted to the connector housing2, the securing latch46may advantageously be supported by an inner surface56of the first terminal passage's4wall22. Therefore, a deflection of the securing latch46radially outwards for disengaging the first terminal10may be prevented, further securing the first terminal10within the terminal support12.

In order to secure the relative rotational position of the first terminal10and the terminal support12and/or ensure coupling of the first terminal10in a predetermined relative rotational position, the first terminal10and the terminal support12may comprise complementary formed keying features58, of which only the keying feature58of the terminal support12is shown inFIGS.2and3. The keying feature58of the terminal support12may be formed as a slot60extending essentially parallel to the longitudinal axis L of the first terminal passage4, the slot60being open towards the second terminal passage6and separating two parts of the support collar40. In an embodiment, the slot60may be arranged opposite the securing latch46and may separate two parts from the remainder of the support collar40in the circumferential direction.

The slot60may be arranged opposite the at least one securing latch46separating two parts from the remainder of the support collar40in the circumferential direction. Therefore, the two parts of the support collar40being arranged adjoining to the slot60, or at least one of the two, may be formed rather rigidly, for example by extending over a larger arc in the circumferential direction and/or a lower length essentially parallel to the longitudinal axis L of the first terminal10. The rigidity of the support collar40adjoining the slot60may further secure the rotational lock provided by the complementary formed keying feature58.

A rail may be provided as the complementary keying feature58formed on the first terminal10. The rail may protrude radially outwards from the first terminal10, particularly the interface end30of the first terminal10shown inFIG.2, and may be adapted to be fittingly received in the slot60, so that relative rotational position of the first terminal10and the terminal support12is secured in a form fitting manner.

To ensure that the first terminal10, particularly the connection end38, does not interfere with the second terminal when the terminal support12is secured in the first position P shown inFIG.1, the first terminal10, the connection end38may be arranged outside the intersection region8. Therefore, the operator may insert the second terminal80into the second terminal passage6without risking damaging one of the terminals; particularly, shearing of the conductor32upon insertion of the second terminal80can be averted. The connection end38can be arranged in the intersection region8in the second position C.

A mode of securing the terminal support12in at least one of the first position P and the second position C is to secure the terminal support12against movement in at least one direction essentially parallel to the longitudinal axis L of the first terminal passage4by a form lock. In this case, the terminal support12may be a terminal position assurance61. For this, the terminal support12may comprise a locking latch62, which can be seen inFIGS.2and3as well asFIGS.7and8. The locking latch62may be elastically deflectable and extend from the front face44into the first terminal passage4, essentially parallel to the longitudinal axis L. In an embodiment, the locking latch62may comprise a larger length essentially parallel to the longitudinal axis L of the first terminal passage4than the support collar40, particularly the securing latch46.

The locking latch62may be adapted to lock the terminal support12, at least in the first position P, and in an embodiment in both positions P, C. Therefore, the operator does not have to worry about accidental movement of the terminal support12during insertion of the second terminal80into the second terminal passage6. The operator does not have to hold the terminal support12or the first terminal10and thus has both hands to his/her disposal for the insertion of the second terminal80.

In an embodiment, the at least one locking latch62and the connector housing2may form a form lock in at least one of the first and second position P, C. With the form lock, wear on the connector housing2as well as the terminal support12may be reduced and lower forces may be necessary to push the terminal support12from the first position P to the second position C or vice versa. Only an initial force for deflecting the at least one locking latch62out of engagement of the form lock is necessary for inducing a relative movement of the terminal support12essentially parallel to the longitudinal axis L relative to the first terminal passage4.

A snap nose64may be formed on a free end of the locking latch62, protruding radially inwards and being adapted to engage a notch63formed on an outer surface of a wall65of the first terminal passage4. The wall65may be adapted to extend into a gap formed between the locking latch62on one side and the support collar40and/or first terminal10on the other side, so that the locking latch62may slide along the outer surface of the wall65, shown inFIG.7. Therefore, movement parallel to the longitudinal axis L may be prevented due to the latching engagement of the snap nose64and the notch63.

In order to provide sufficient space for the locking latch62to be elastically deflected to disengage the notch, a play67may be provided radially outwards from the locking latch62in the radial direction. The locking latch62may extend in the circumferential direction along an arc section, the arc section being arranged circumferentially shifted to the support collar40.

Additionally or alternatively, the arc section, along which the locking latch62extends, may be radially offset from the support collar40. Therefore, the support collar40does not disrupt the freedom of a deflection movement of the locking latch62.

As can be seen inFIG.1for example, the first terminal passage4may comprise a radially widened entry66distal to the second terminal passage6essentially parallel to the longitudinal axis L of the first terminal passage4. The entry66may be adapted to fittingly receive the support collar40such that the support collar40may not be deflected radially outwards. Additionally, the entry66may be adapted to receive the locking latch62.

For stabilizing the first terminal10within the first terminal passage4, the first terminal passage4may comprise a radial constriction68, shown inFIG.1, in which the first terminal10is fittingly held. The radial constriction68may extend from the entry66to the distal end section26of the first terminal passage4that is arranged in the intersection region8.

In an embodiment, the terminal support12may further comprise a guiding collar70shown inFIG.1for guiding the movement between the terminal support12and a mating connector, particularly the movement of the terminal support12essentially parallel to the longitudinal axis L along the first terminal passage4. The guiding collar70may surround the support collar40and the locking latch62forming a radial outer wall of the terminal support12. In an embodiment, the guiding collar70may extend from the front face44in direction essentially parallel to the longitudinal axis L of the first terminal passage4towards the second terminal passage6.

A gap71may be formed between the guiding collar70and the support collar40and/or the locking latch62, whereby the wall22of the first terminal passage4may be received in said gap71essentially parallel to the longitudinal axis L of the first terminal passage4.

In an embodiment, the front face44is closed between the support collar40and the guiding collar70so that the wall22may abut against the inner surface of the front face44when pushing the terminal support12too deep into the first terminal passage4, as shown inFIG.5. When at least one locking latch62is adapted to deflect radially outwards, the at least one locking latch62may be surrounded by the guiding collar70and may be radially distanced to the guiding collar70, so that space is provided for the locking latch62to deflect radially outwards.

The guiding collar70may rest on the outer surface20of the wall22, whereby the guiding collar70may circumferentially surround the wall22at least partially. Therefore, a tilting of the terminal support12relative to the connector housing, particularly the first terminal passage4, may be averted.

The guiding collar70may comprise at least one guiding slot72, shown inFIG.2, extending from the front face44essentially parallel to the longitudinal axis L of the first terminal passage4towards the second terminal passage6. In this exemplary embodiment, the guiding collar70extends circumferentially along an essentially rectangular shape having two opposing narrow sides and two opposing wide sides connecting the narrow sides to one another. Each side may comprise a guiding slot72, wherein the guiding slots72arranged at the narrow sides may be arranged at the center of said sides opposing each other. The guiding slots72arranged at the wide sides may be arranged opposite each other off-center of the wide sides. In an embodiment, the guiding slots72may be arranged off center at one side. If the guiding collar70comprises an essentially rectangular configuration, the two opposing narrow sides may have the guiding slots72arranged centrally on said narrow sides and the guiding slots72arranged on the wider sides may be arranged off center.

The guiding slots72may further act as a polarization feature signaling the correct rotational position for mounting the terminal support12to the connector housing2and/or for mating the mating connector with the angled connector1. In order to prevent the mating connector for being pushed too far into the first terminal passage4beyond the terminal support12, the at least one guiding slot72may be closed at a distal end73directed towards the second terminal passage6, e.g. by a bridge74as shown inFIG.2. Complementary to the guiding slots72, guiding ribs may be provided on the mating connector, which may be adapted to be received in the corresponding guiding slots72. The radially protruding rib abuts the bridge74when mating the mating connector with the angled connector1essentially parallel to the longitudinal axis L out of the first terminal passage4.

The angled connector1may be pre-assembled in the first position P, as shown inFIG.1, at a manufacturing site. In the first position P, the first terminal10, particularly the connection end38of the first terminal10, does not intersect an insertion path of the second terminal for insertion into the second terminal passage6. The terminal support12may be secured in the first position P essentially parallel to the longitudinal axis L in a form locking manner preventing movement of the terminal support12further into the first terminal passage4towards the second terminal passage6. Therefore, the operator may further concentrate solely on the insertion of the second terminal80before directing the attention to completing the connection by pushing the terminal support12into the second position C.

As is shown inFIGS.4and5, the second terminal80may be inserted into the second terminal passage6until abutment against an abutment surface82formed at the distal end section26essentially perpendicular to the longitudinal axis L of the second terminal passage6. The abutment surface82may be formed on the inner surface56of the first terminal passage4's wall22at the intersection region8, as shown inFIG.1.

The second terminal80may be a cable end terminal84being assembled onto an end of an electric cable86, for example by crimping or the like, as shown inFIGS.4and5. A seal88, circumferentially surrounding the electric cable86, may be provided to seal the entry of the second terminal passage6distal to the first terminal passage4and the intersection region8. The seal88may be compressed between an outer surface of the cable86and an inner surface of a wall of the second terminal passage6.

According to the inventive method, the terminal support12is secured in the first position P shown inFIG.4before insertion of the second terminal80into the second terminal passage6, shown inFIG.5. The second terminal80may be inserted until abutment against the abutment surface82, signaling the operator that the second terminal80is positioned in an assembly position A. In the method, the terminal support12is secured in the first position P before the second terminal80is inserted into the second terminal passage6into the assembly position A. The abutment of the second terminal80with the abutment surface82indicates to an operator that the terminal support12may be safely pushed into the second position C from the first position P to connect the terminals10,80with one another.

Consequently, the operator may push the terminal support12from the first position P into the second position C pushing the connection end38into engagement with the second terminal80, as is shown inFIG.5. As can be seen inFIG.6, the wall65may comprise two notches63formed on the outer surface of the wall65. The two notches63may be spaced apart from one another along the longitudinal axis of the first terminal passage4, so that a first notch63being distal to the second terminal passage6may engage the snap nose64in a form locking manner in the first position P, as shown inFIG.7. By exerting a pushing force to the terminal support12, the locking latch62may be deflected radially outwards so that the form lock is released and the terminal support12may be pushed further into the first terminal passage4towards the intersection region8.

In an embodiment, the terminal support12may be secured in the second position C essentially parallel to the longitudinal axis L of the first terminal passage4in a form locking manner by having the snap nose64engage a second notch63proximal to the second terminal passage6, as shown inFIG.8. The form lock may at least prevent movement of the terminal support12out of the first terminal passage4away from the second terminal passage6essentially parallel to the longitudinal axis L of the first terminal passage4. Hence, the connection between the first terminal10and the second terminal80may be further secured by the terminal support12preventing accidental disengagement due to high stress, such as vibrational stress.

With the inventive solution, the first terminal10may be pre-mounted at the manufacturing site, while the second terminal80may be mounted on site by the operator. Therefore, the operator does not need additional equipment for processing the first terminal10. The first terminal10may be mounted and secured in the first position P at the manufacturing site, wherein in the first position P, the first terminal10does not interfere with the second terminal80. Thus, the operator may easily insert the second terminal80into the second passage6in the assembly position A without risking damage to any of the terminals10,80. Once the second terminal80is in the assembly position, the operator may push the terminal support12into the second position C, so that the first and second terminals10,80may be connected to one another in a form- and/or force-locking manner.