Housing Assembly for a Module Connector with Pre-Locked Screw

The invention relates to a housing assembly protected against contact for a module connector, with a housing which comprises a passage opening extending through the housing in a direction of connection, and with a screw with a screw head arranged in the passage opening, where the screw is locked in the passage opening in a pre-assembly position. Such a housing assembly can be assembled quickly and in a simple manner and at the same time is completely protected against contact.

This application claims priority to and the benefit of German Patent Application No. 102023115674.8 filed Jun. 15, 2023, which is hereby incorporated by reference in its entirety.

The present invention relates to a housing assembly for a module connector.

Module connectors are used, for example, to connect electrical modules, such as battery cells of batteries, in particular drive batteries of vehicles, to one another in an electrically conductive manner. In order to connect the current-carrying components of the electrical modules to one another in an electrically conductive manner, module connectors typically comprise a screw or other fastening devices. Module connectors can also be used to electrically connect consumers, fuses, or BDUs.

For assembly, an interface of the module connector is aligned relative to an interface of the electrical module. The module connector and the module are thereafter screwed together. This alignment and assembly can be quite time consuming.

The present invention is therefore based on the object of providing a housing assembly for a module connector that can be assembled quickly and in a simple manner. At the same time, the housing assembly is to be completely protected against contact.

This object is satisfied by a housing assembly protected against contact for a module connector,with a housing which comprises a passage opening extending through the housing in a direction of connection, andwith a screw having a screw head, the screw being arranged in the passage opening,where the screw is locked in the passage opening in a pre-assembly position.

Before the module connector is assembled with an electrical module, the housing assembly is aligned relative to a housing of the electrical module to be connected. During alignment, the housing of the housing assembly of the module user is there displaced relative to the housing of the electrical module to be connected until the longitudinal axes of the two housings are aligned or the screw can be inserted through all of the parts to be connected to one another. For alignment, the screw of the housing assembly according to the invention is locked in the passage opening in a pre-assembly position. This means that the screw is fastened in the housing—in particular in a captive manner—which simplifies assembly.

The invention can be further improved by the following features which are advantageous by themselves and which can be combined with one another at random.

For example, it is advantageous to have the screw or screw shank not protrude from the housing in the pre-assembly position. This will prevent damage to other parts when the module connector is finally assembled. Since the screw or screw shank does not protrude from the housing, it cannot scratch other parts when aligning the screw.

According to an advantageous embodiment, the screw head can comprise a screw flange and can be configured to be protected against contact, and the screw head can be locked in the passage opening. The screw flange or the insulating material of the screw flange can be part of the protection against contact of the housing assembly, i.e. be made of electrically insulating material. By locking the screw head in the passage opening, the screw is secured in a captive manner to the housing. In particular, it is prevented that the screw moves along its longitudinal axis during assembly and obstructs the alignment of the housing relative to a housing of an electrical module to be connected. A screw flange is advantageous in that it bridges a gap between the screw or the screw head and the passage opening which has a larger diameter than the screw. This configuration is a structurally simple way to realize a lock between the screw head and the passage opening.

According to a further aspect, the passage opening can be closed by the screw flange—in particular in a manner protected against contact. This configuration prevents objects or human fingers from being inserted into the passage opening of the housing assembly from the outside and thus coming into contact with current-carrying components of the module connector. Such a housing assembly consequently increases application safety. Furthermore, the ingress of dirt is prevented, which could impair the functionality and safety of the module connector.

According to a further embodiment, the screw head can be disposed in the pre-assembly position at one end of the passage opening and a screw shank of the screw can extend through the passage opening or be disposed in the passage opening. At the end of the through hole, the screw is in the maximum retracted position. The passage opening is therefore closed at the very top so that no dirt can accumulate.

In particular, the screw flange can be disposed at one end of the passage opening and the screw head can protrude from the passage opening. The housing assembly according to this embodiment is particularly easy to assemble because the screw head is easily accessible to human hands or tools.

According to a further embodiment, the passage opening can comprise a locking projection that projects in the radial direction inwardly. Such a locking projection represents a structurally simple and therefore inexpensive way of locking the screw in the passage opening.

According to a further advantageous embodiment, the at least one locking projection can be formed by a locking tongue which can be resiliently deflected in the radial direction. As a result, the lock between the screw and the passage opening created by way of the locking tongue is configured to be releasable. This is advantageous if the screw has to be transferred from the pre-assembly position to an assembly position. For this purpose, the screw can be pressed along its longitudinal axis into the passage opening of the housing assembly. As a result, the at least one locking tongue is deflected in the radial direction outwardly and the lock is released. After the lock has been released, the locking tongues can also snap back in the radial direction inwardly to their starting position due to their resilience. Such a configuration is reversible so that the pre-assembly position of the screw can be established again even after the lock has been released.

A foot of the locking tongue, which can extend away from the foot in the direction of connection, can be connected to a wall of the passage opening. The connection can in particular be configured to be monolithic. Furthermore, a free end of the locking tongue can comprise a locking tab and the locking tongue can be arranged in a recess in the wall.

According to a further aspect, the passage opening can comprise a wall that comprises a pocket which is offset in the radial direction outwardly and in which locking projections are received. The wall or the passage opening can be substantially cylindrical. The pockets ensure that the locking projections cannot be touched by objects or hands from the outside and then be damaged. In particular, the locking projections are prevented from breaking off.

According to a further advantageous embodiment, the housing can comprise a collar which surrounds the passage opening and projects on the side of the housing facing away from the screw head, and where the screw does not protrude from the collar in the pre-assembly position. By use of such a collar, the housing assembly can be aligned relative to an electrical module and plugged together before the housing assembly is screwed to the electrical module. The collar can be, for example, inserted into or placed onto a collar of the electrical module that is configured to be complementary. By having the screw not protrude from the collar of the housing assembly in the pre-assembly position, an end of the screw facing away from the screw head is prevented from coming into contact with the mating contact of the electrical module during alignment. This prevents damage to the mating contact of the electrical module.

A contact ring into which the screw at least protrudes can be received in the housing. The screw can also protrude through the contact ring or, in particular, not protrude from the contact ring. Preferably, the contact ring can be received in the passage opening or in the collar of the passage opening. The contact ring can be displaceable in the receptacle for a bus bar, in particular to establish contact between the bus bar and the contact ring.

According to a further advantageous embodiment, at least two locking projections disposed diametrically opposite one another with respect to the direction of connection can be present. If a screw locked to the housing by way of the locking projections is loaded along its longitudinal axis, then the forces must be absorbed by the locking projections. Arranging the locking projections symmetrically relative to the direction of connection ensures that the screw does not cant when loaded in the longitudinal direction. This makes assembly easier because the screw thread is prevented from canting in the complementary internal thread of the electrical module. Furthermore, it is ensured that the lock of the screw does not come loose on one side or both sides.

According to a further aspect, the housing assembly can comprise an outer housing in which the housing is received to be displaceable in at least one direction of displacement that is disposed in a plane perpendicular to the direction of connection. Due to the displaceability of the housing relative to the outer housing, the screw is likewise displaceable in the plane perpendicular to the direction of connection. This allows positional tolerances to be compensated for when connecting electrical modules. The connection of electrical modules is therefore force-free, which reduces the mechanical load on the module connector and the electrical modules.

The housing can be held in the direction of connection substantially firmly or immovably in the outer housing.

According to a further embodiment, two locking projections disposed diametrically opposite one another can be spaced from one another in the direction of displacement. In particular, the locking projections and the center of the passage opening can be disposed on a connecting line.

In order to move the housing together with the screw along the direction of displacement during alignment, a user typically exerts a force in the region of the screw head. This force can tilt the screw in the housing perpendicular to the direction of displacement, making alignment difficult. Due to the special arrangement of the locking projections, the connecting line of which extends along the direction of displacement or perpendicular to the axis of rotation, respectively, tilting of the screw during the displacement motion can be prevented.

According to a further embodiment, the outer housing can comprise a bus bar receptacle in which a bus bar can be received substantially perpendicular to the direction of connection, where the bus bar receptacle penetrates the passage opening. By providing a bus bar receptacle, the housing assembly can be used to connect electrical modules that have a bus bar. Such a housing assembly can therefore be used in a flexible manner.

The housing assembly can comprise a bus bar, where the bus bar can extend through the passage opening perpendicular to the direction of connection. The bus bar can have an insertion opening through which the screw can protrude. The insertion opening can be a long hole that can extend in the direction of displacement. The housing, together with the screw, can be displaceable in the direction of displacement relative to the bus bar.

According to a further advantageous embodiment, the housing can comprise a collar through which the passage opening extends. In particular, the collar can form the end of the passage opening. The collar provides the advantage that a complementary housing member of an electrical module to be connected can be aligned at the collar and plugged together therewith. This makes assembly easier. Furthermore, the collar can surround current-carrying components of the housing assembly, such as a contact ring, and thereby contribute to the protection against contact.

Furthermore, the housing can comprise at least one flange section which can extend along a plane that runs substantially perpendicular to the direction of connection or in the direction of displacement. The flange section can surround the passage opening and/or run parallel to a plane extending perpendicular to the direction of connection. The flange section can be longer in the direction of displacement than transverse to the direction of displacement. Furthermore, the collar can end at the flange section.

The flange sections can be planar and the flange sections can each abut in a displaceable manner against a housing section of the outer housing which respectively forms a displacement opening. A flange section there closes the displacement opening at least in part, but preferably completely. In particular, the flange section closes the displacement opening in every position of the housing relative to the outer housing. In this way, the protection against contact of the housing assembly is ensured in every position of the housing relative to the outer housing.

Each flange section can close a displacement opening—in particular in every position of the housing that is displaced in the direction of displacement relative to the outer housing. The displacement opening can be disposed between the collar and the edge of the passage opening.

The housing can also comprise two flanges spaced from one another in the direction of connection. The flanges can be connected to one another by the wall of the passage opening.

According to a further advantageous embodiment, the screw head can be locked in the collar. By locking the screw head in the collar, the screw is connected to the collar in a motion-transmitting manner. The screw can be aligned in this way without the screw having to move relative to the housing.

The housing assembly can comprise a second housing which can be plugged together with the housing and/or with the outer housing to receive a second bus bar and in which a collar that is formed to be complementary to the passage opening can be configured. A second contact ring can be received in the collar that is formed to be complementary.

In a state in which the housing and/or the outer housing are plugged together ready for operation, the screw can protrude through the contact ring. In particular, the screw can also protrude through the second bus bar in this state.

In the state in which the housing and/or the outer housing and the second housing are plugged together ready for operation, the contact ring and the second contact ring can lie on top of one another in an electrically conductive manner. In particular, the bus bar and the second bus bar can be connected to one another in an electrically conductive manner by way of the contact ring and the second contact ring. The screw can be part of a screw connection that generates a preload force that presses the bus bar, the contact ring, the second contact ring, and the bus bar together.

According to a further embodiment, the outer housing can comprise at least one displacement opening through which the collar of the housing extends, and the displacement opening can be a long hole whose longitudinal direction extends in the direction of displacement. The provision of a displacement opening in the outer housing represents an advantageous structural configuration in order to enable displaceability of the housing relative to the outer housing. Since the screw can be connected to the housing in a motion-transmitting manner, the screw as well can be displaceable relative to the outer housing. In this way, positional tolerances between two electrical modules to be connected can be compensated for. The configuration of the displacement opening as a long hole restricts the movability of the housing and therefore of the screw to the longitudinal direction of the long hole.

The outer housing can preferably also comprise two displacement openings spaced from one another in the direction of displacement through which a collar of the housing extending in the direction of displacement extends.

In the following, the invention shall be explained in more detail by using embodiments with reference to the appended drawings. Individual features that are present in the following embodiment can then be omitted if, according to the above embodiments, the technical effect associated with this feature is not important. Conversely, a feature described above but not present in an embodiment below can be added to the embodiment if the technical effect associated with this feature is important for a specific application.

The structure and function of the housing assembly shall first be described with reference toFIGS.1to4. The assembly of the housing assembly shall be described thereafter with reference toFIGS.4and5.

Housing assembly1comprises an outer housing2, a housing4, a screw6, a contact ring8, and a bus bar10.

Housing4comprises a passage opening12, longitudinal axis14of which extends along a direction of connection16through housing4. Passage opening12is surrounded by a substantially cylindrical wall18which is arranged concentrically around direction of connection16or around a longitudinal axis14of passage opening12, respectively. A lower part20of housing4comprises a collar22which projects on side26of housing4facing away from a screw head24. In particular, passage opening12extends through collar22, and collar22forms an end28of passage opening12. Collar22concentrically surrounds substantially cylindrical contact ring8.

Housing4also comprises at least one flange section30which projects vertically from housing4. In the embodiment shown, an upper part32of housing4as well as collar22of lower part20of housing4comprise a flange section30. Flange sections30run parallel to one another and to a displacement plane34which extends perpendicular to direction of connection16. Flange sections30are substantially planar and configured to each abut in a displaceable manner against a section36of outer housing2. In the embodiment shown, flange sections30are longer in a direction of displacement38than transverse to direction of displacement38. Direction of displacement38extends along displacement plane34.

As can be clearly seen fromFIGS.3and4, upper part32of housing4comprises locking projections40which are disposed opposite one another relative to longitudinal axis14of passage opening12or relative to direction of connection16, respectively. A connecting line42between locking projections40extends along direction of displacement38. Locking projections40are configured to engage in a lock44with screw6extending through passage opening12.

In the embodiment shown inFIG.3, locking projections40are configured as locking tongues46which extend from a foot48up to a free end50. Feet48of locking tongues46are connected to upper part32of housing4or to wall18, where the connection is preferably monolithic. Locking tongues46can be resiliently deflected in a radial direction52which extends perpendicular to direction of connection16. Locking tongues46comprise a locking tab54at their free ends. Locking tabs54are configured to abut against a screw flange56of screw6.

Upper part32of housing4comprises pockets58in which locking projections40or locking tongues46are received. Pockets58represent bulges60which extend in the radial direction outwardly60and along direction of connection16or along a longitudinal axis62of screw6, respectively. Pockets58can also be formed by wall18of passage opening12. Pockets58are provided to protect locking projections40or locking tongues46from being touched by objects or fingers and thereby prevent damage.

Housing4is surrounded at least in part by outer housing2. Outer housing2comprises a bus bar receptacle64in which bus bar10is received perpendicular to direction of connection16. Bus bar10comprises a passage opening66which represents a long hole68in the illustrated embodiment.

Outer housing2comprises displacement openings70which are disposed opposite one another with respect to displacement plane34and are spaced from one another in direction of displacement38. A displacement opening70can be configured as a long hole72, longitudinal direction74of which extends along direction of displacement38. Upper part32of housing4extends along direction of connection16through displacement opening76of an upper outer housing member78, and collar22of lower part20of housing4extends along direction of connection16through displacement opening80of a lower outer housing member82.

Displacement opening76of upper outer housing member78in relation to direction of connection16comprises oppositely disposed recesses84which are curved to be complementary to pockets58of upper part32of housing4. In this way, pockets58of housing4can be received by recesses84of upper outer housing member78when housing4is displaced along direction of displacement38.

Regardless of how housing4is displaced relative to outer housing2along displacement plane34or direction of displacement38, respectively, both displacement openings76,80are closed in a touch-safe manner. In particular, displacement opening76of upper outer housing member78is closed by screw flange56and flange section3of upper part32of housing4.

Screw6is provided for connecting housing assembly1to a second housing assembly86(seeFIG.4). Screw6is arranged in passage opening12such that longitudinal axis62of screw6extends along longitudinal axis14of passage opening12or along direction of connection16, respectively. Screw6comprises a screw shank88, screw head24, and screw flange56. Screw shank88provides an external thread90which is configured to engage with a complementary internal thread91of second housing assembly86.

Screw head24protrudes from housing4in direction of connection16and comprises a cap92which is preferably manufactured from insulating material. Screw flange56is arranged at an end94of screw head24facing external thread90and extends in a rotationally symmetrical manner about longitudinal axis62of screw6. Screw flange56is part of the protection against contact and is preferably manufactured from insulating material.

In a pre-assembly position96, screw6is locked in passage opening12so that screw6is held in an upper position98. In upper position98, screw head24is spaced as far as possible from end100of collar22of lower part20of housing4facing away from screw head24. In pre-assembly position96, an end102of screw6facing away from screw head24does not protrude in direction of connection16at end100of collar22facing away from screw head24.

Lock44of screw6in passage opening12is realized in the embodiment shown inFIG.4in that an underside104of screw flange56rests upon free ends50of locking projections40which in radial direction105point inwardly. In particular, underside104of screw flange56can rest upon locking tabs54which are arranged on free ends50of locking tongues46.

Screw6is mounted to be rotatable about longitudinal axis62of screw6relative to housing4, to outer housing2, to bus bar10, and to contact ring8of housing assembly1. In addition, screw6is connected to housing4in a motion-transmitting manner so that housing4together with screw6can be displaced relative to outer housing2in direction of displacement38. If housing assembly1comprises a bus bar10, then housing4together with screw6can likewise be displaced relative to bus bar10in direction of displacement38. In particular, housing4with screw6can be displaceable relative to outer housing2along displacement plane34. If housing assembly1comprises a bus bar10with a long hole68, then housing4together with screw6can only be displaced along a longitudinal axis106of long hole68.

It is described hereafter with reference toFIGS.4and5how housing assembly1is assembled with a second housing assembly86.

Second housing assembly86comprises a housing108with a collar110which is configured to be complementary to passage opening12of housing assembly1Collar110of second housing assembly86is configured such that it can be plugged together with collar22of housing assembly1. A contact ring112is received in collar110of the housing of second housing assembly86. Contact ring112of second housing assembly86is provided to come into electrically conductive contact with contact ring8of housing assembly1.

At the beginning of the assembly, screw6of housing assembly1is in the pre-assembly position96. In pre-assembly position96, screw6is locked in passage opening12. Screw6is held in upper position98, so that end102of screw6facing away from screw head24does not protrude along direction of connection16at end100of collar22of housing assembly1facing away from screw head24. In this way, end102of screw6facing away from screw head24is prevented from coming into contact with contact ring112or collar110of second housing assembly86before housing assembly1is aligned relative to second housing assembly86or before housing assembly1is plugged together with second housing assembly86, respectively. This prevents damage to contact ring112or to collar110of second housing assembly86.

In the first assembly step, housing assembly1is aligned relative to second housing assembly86. For this purpose, collar22of housing assembly1is displaced along displacement plane34or along direction of displacement38until a longitudinal axis114of collar22of housing assembly1extends along a longitudinal axis116of collar110of second housing assembly86.

Screw6is therefore aligned together with collar22of housing assembly1and collar110of second housing assembly86to fit because all movable parts of housing assembly1are connected to one another in a motion-transmitting manner. If collar22of housing assembly1is displaced along direction of displacement38or along displacement plane34during alignment, then the motion of collar22continues onto contact ring8of housing assembly1because contact ring8is inserted into collar22of housing assembly1. As a result, contact ring8transmits the motion along direction of displacement38or along displacement plane34to screw shank88because the latter extends at least in part in direction of connection16through contact ring8. The motion of screw6along direction of displacement38or along displacement plane34is in turn transmitted to upper part32of housing4, whereby the latter also moves along direction of displacement38or along displacement plane38, respectively.

Once the alignment process has been completed, housing assembly1and second housing assembly86can be plugged together along direction of connection16. Collar22of first housing assembly1is placed over collar110of second housing assembly86, or collar22of first housing assembly1is inserted into collar110of second housing assembly86.

After housing assembly1and second housing assembly86have been aligned and plugged together, there is no longer any danger that an end102of screw6facing away from screw head24can damage contact ring112or collar110of second housing assembly86. The pre-assembly position96of screw6can therefore be cancelled.

For this purpose, lock44of screw6in passage opening12is released. Screw6is there pressed along its longitudinal axis62or along direction of connection16in the direction of second housing assembly86, whereby locking tongues46are resiliently deflected in the radial direction outwardly60by underside104of screw flange56. In particular, free ends50of locking tongues46are deflected resiliently in the radial direction outwardly60. As soon as screw flange56has overcome free ends50of locking tongues46or locking tabs54disposed at free ends50of locking tongues46along direction of connection16, screw flange56is no longer held by locking tongues46. This releases lock44of screw6in passage opening12, whereby screw6slips along direction of connection16and in the direction of second housing assembly86into passage opening12. At the same time, locking tongues46, which are deflected resiliently in the radial direction outwardly60, snap back in the radial direction inwardly105. This can prevent screw6from dropping out of housing assembly1.

After the plugging process, contact ring8of housing assembly1and contact ring112of second housing assembly86lie on top of one another in an electrically conductive manner. In particular, bus bar10of housing assembly1can be connected in an electrically conductively manner to a bus bar of second housing assembly86. Screw6protrudes through contact ring8of the housing assembly and contact ring112of second housing assembly86. Furthermore, screw6can also protrude through the bus bar (not shown) of second housing assembly86.

In a final assembly step, screw6is fastened. Screw6generates a preload force that compresses bus bar10and contact ring8of housing assembly1as well as bus bar118and contact ring112of second housing assembly86along longitudinal axis62of screw6. In this way, the current-carrying components of housing assembly1and second housing assembly86are electrically connected to one another and the assembly is completed.

In this state, all current-carrying components of housing assembly1and second housing assembly86are surrounded without a gap by non-conducting components. In this way, complete protection against contact is guaranteed. In particular, contact of a human finger or objects with current-carrying components is prevented.

REFERENCE NUMERALS

1housing assembly2outer housing4housing6screw8contact ring10bus bar12passage opening14longitudinal axis of the passage opening16direction of connection18wall20lower part of the housing22collar24screw head26side of the housing facing away from the screw head28end of the passage opening30flange section32upper part of the housing34displacement plane36section of the outer housing38direction of displacement40locking projection42connecting line44lock46locking tongue48foot50free end52radial direction54locking tab56screw flange58pocket60radial direction outwardly62longitudinal axis of the screw64bus bar receptacle66passage opening of the bus bar68long hole of the bus bar70displacement opening72long hole of the displacement opening74longitudinal direction of the long hole of the displacement opening76displacement opening of the upper outer housing member78upper outer housing member80displacement opening of the lower outer housing member82lower outer housing member84recesses86second housing assembly88screw shank90external thread91internal thread of the second housing assembly92cap94end of the screw head facing the external thread96pre-assembly position98upper position100end of the collar facing away from the screw head102end of the screw facing away from the screw head104underside of the screw flange105radial direction inwardly106longitudinal axis of the long hole108housing of the second housing assembly110collar of the second housing assembly112Contact ring of the second housing assembly114longitudinal axis of the collar of the housing assembly116longitudinal axis of the collar of the second housing assembly