Connector

The connector includes an electrically insulating one-part or multi-part housing, in which at least one contact element is arranged, which is accessible via a first opening of the housing by a contact element of a complimentary second connector, and which is connectable with an electrical cable that can be introduced through a second opening of the housing. The housing of the assembled connector, which is made from a first material, includes at least a first coupling element, which corresponds to at least one second coupling element that is included on a tubular element, which is manufactured from a second material which after processing includes a higher mechanical strength than the first material, and wherein the housing is releasably held within the tubular element by the releasably interlinked coupling elements.

The present invention relates to a connector comprising an electrically insulating housing consisting of one or more parts and at least one contact element that is arranged in said housing and is accessible through a first opening in the housing by a contact element of a complementary connector and that is connectable with an electrical cable, which is introduced through a second opening into the housing.

Connectors of this kind, which are known e.g. from [1], US2011294324A, must meet various requirements that differ from one field of application to another.

Connectors used in photovoltaic systems must meet especially high requirements as defined in national standards. Required are for example a high creep resistance or a very good CTI (Comparative Tracking Index) value, a high level of fire protection as well as high mechanical strength, particularly good mechanical impact strength at low temperatures.

According to known standards the test for mechanical impact resistance is executed, by cooling down samples to −40° and then exposing the samples to mechanical shocks having an energy of 1 Joule. According to other standards a higher mechanical impact energy, e.g. of 6.8 J is applied. The test is passed, then no damage occurred, that would affect usability of the connector.

With special materials, it is possible to meet individual requirements relatively easily. However, difficulties arise when different requirements need to be met simultaneously. Depending on the material used, for example the required creep resistance is reached, but not the impact resistance. In the event that different requirements need to be met, the dimensions of plugs and sockets are increased under consideration of the selected material until all requirements are met. In the event that the connectors are used for high-voltage applications, then under consideration of the applied material dimensions of the housing are selected that provide correspondingly large creeping current distances.

By these measures not only undesirable large dimensions of the connectors but also high manufacturing costs result.

E.g. from [2], US 2010/0323554 A1, a connector with a housing is known, which serves for receiving and holding a plurality of base elements and contact elements. Furthermore, the housing comprises flange elements, with which the connected can be mounted for example on a printed circuit board. The connector and the housing are therefore designed for a specific application. In the event that different requirements are given, then another connector must be selected.

It should be noted that similar connectors are widely used in various application areas, in which entirely different requirements need to be met. Even if lower requirements are frequently given, often still only one type of connector is stored and used, which meets also higher requirements, and thus is relatively expensive.

It further must be noted, that parts of the housing, often need to fulfil further functions and therefore require corresponding characteristics such as a high elasticity.

[3], US2003100215A, discloses a durable data connector assembly for installation onto a cable connector and attached cable, which comprises a housing having positioning means for positioning the cable connector at a predetermined location within the housing and having thread means formed on a surface thereof; a radially-compressible chuck for urging the cable connector to the predetermined location and for gripping the cable; a tapered boot for radially compressing the chuck; and a threaded bushing for arresting the tapered boot and for mating to the threads on the housing in a threaded joint. By tightening the joint the bushing, boot, chuck, housing, and cable connector are compressed together to form the final assembly.

Assembling this connector therefore requires considerable efforts and various parts that cause rather high production costs. The assembly is mounted on a connector that is already connected to a cable. Therefore, all parts of the assembly need to be mounted onto the cable before the connectors are attached to the cable. After the connectors are attached on both ends of the cable, the remaining assembly parts are firmly linked to the cable and can no longer be removed. Consequently mounting of the assembly needs to be done before the connectors are mounted. In the event that the connectors have been mounted without the further assembly parts, then it is no longer possible to equip the cable and connectors with the system disclosed in [3]. Since a large-scale user does not assemble data cables himself, the cables including the connectors and further assembly parts are assembled at the production site. Consequently the user would evaluate what numbers of cables, with or without the enforcing assembly parts, would be required. Since exact numbers can scarcely be obtained in large installation sites, the user or installation manager would order and store various types of cables in excess.

The present invention is therefore based on the object of creating an improved connector, which better fulfils different high demands and which can be produced with lower manufacturing costs.

The improved connector shall be adaptable to the present technical requirements with little effort so that a user does not need to store several types of cables or connectors.

If required, the connector should be adaptable to given requirements such as a possible occurrence of higher mechanical impacts.

Furthermore, it shall be possible to advantageously lock and unlock an inventive connector after it has been connected to another complementary connector.

This object is achieved with a connector that comprises the features of claim1. Preferred embodiments of the invention are defined in further claims.

The connector comprises an electrically insulating one-part or multi-part housing, in which at least one contact element is arranged, which is accessible via a first opening of the housing by a contact element of a complimentary second connector, and which is connectable with an electrical cable that can be introduced through a second opening of the housing.

According to the invention the housing of the assembled connector, which is made from a first material, comprises at least a first coupling element, which corresponds to at least one second coupling element that is provided on a tubular element, which is manufactured from a second material which after processing comprises a higher mechanical strength than the first material, and wherein the housing is releasably held within the tubular element by the releasably interlinked coupling elements.

The first material is selected in such a way, that the housing of the connector is optimised in view of functionality and primary characteristics, such as creep current resistance and/or fire protection. The second material is selected in such a way, that the tubular element is optimised in view of mechanical strength, particularly mechanical strength at low temperatures (low temperature impact resistance).

The inventive connector can therefore be adapted to given requirements at the installation site even after it has been connected to the cable. The tubular element can be mounted to the housing of the connector or released therefrom by interlocking or releasing the coupling elements to or from one another. The coupling elements can be created in such a way, that this action of mounting or releasing the tubular element can be done manually or with a dedicated tool that is only accessible by authorised personnel.

Hence, the user can store one type of connector that is already attached to a cable or that can be attached to the cable at the installation site and that can be equipped with little effort with the tubular element whenever required. This flexibility allows the engineer to decide at the point and time of installation, whether the installed connector requires additional protection are not. A tubular element can be mounted or dismounted within seconds. The installation can therefore be optimised in view of providing optimal protection of the installed connections as well as for most economical use of the resources.

The first material is a first plastic, preferably a modified Polyphenylene (PPE), which provides the housing with good insulation properties, temperature resistance, UV-resistance and adequate elasticity for functional parts, such as lock elements.

The second material is a second plastic, preferably a thermoplastic casting resin, which comprises polyimide-components and Siloxane-Copolymer-Components. Materials of this kind, which are known for example from [4], US6011122A and [5], US2004232598A1, exhibit a high temperature resistance as well as a high mechanical strength particularly at low temperatures.

With the inventive combination of these materials an optimised connector is achieved, which optimally satisfies various strict requirements and which therefore can advantageously be used for the most demanding conditions, e.g. in photovoltaic systems. The connector is not limited in its functionality and is optimally protected by the tubular element against mechanical impacts as well as contamination and thus maintains optimal electrical properties.

Preferably, the tubular element is used only then, when protection against mechanical impact is required. Depending on the requirements, the connector is therefore used with or without tubular element. In an electrical system, e.g. in a photovoltaic system, always the same type of connector can be used. For parts of the system, which are exposed to weather and mechanical impacts, e.g. in the connection field of solar energy modules, the connector is equipped with the tubular element.

For the connection of electrical cables in a protected area, e.g. in the range of an energy distribution unit, the connector can be used without a tubular element.

Hence, an inexpensive and small connector can be used and adapted to any given installation condition. For this reason, low costs occur for purchasing, storing and selectively using the unitary connector.

The dimensions of the tubular element, particularly its length, are adapted to the housing of the connector, so that at least the impact sensitive zone of the housing, preferably the complete housing, with or without extremities, is optimally protected.

The tubular element can easily be manufactured in dimensions which provide high stability. Preferably the tubular element is designed hollow-cylindrically, so that mechanical tension resulting from mechanical impacts is uniformly distributed across the tubular element, and not transferred or strongly reduced transferred to the housing of the connector. The tubular element, which is adapted to the housing of the connector, can be mounted onto the connector in the form of a slim sleeve. Therefore the dimensions of the connector are scarcely increased after mounting the tubular element. Compared to conventional connectors having increased dimensions for meeting given requirements the inventive connector exhibits with improved properties comparable or even reduced dimensions. Due to the cylindrical design of the tubular element a connector protected therewith exhibits a compact outer surface, which satisfies aesthetic requirements of professional products and scarcely requires cleaning and maintenance.

The tubular element can be coupled to the housing of the connector in various ways. The housing of the connector and the interior side of the tubular element are provided for example with coupling elements, which are designed as threaded elements corresponding to one another, as screws and threaded holes corresponding to one another, as openings and arresting bolts corresponding to one another or as openings and hooks corresponding to one another.

Preferably the coupling elements are integrated in one piece in the housing of the connector or in the tubular element, so that a minimal production effort is required.

The housing of the connector preferably comprises at least one receiving opening that is used and formed as a coupling element, into which the coupling elements of the tubular element can engage. In a further preferred embodiment, at least one pair of receiving openings is provided, so that a particularly stable connection is achieved. If a plurality of pairs of receiving openings is provided, then the tubular element can be arranged and fixed element at a desirable position.

In the event that two connectors are connected with one another, then it is sufficient, if only one of the connectors is provided with a tubular element, which at least partially, covers both connectors. In this embodiment the common tubular element can also serve as a locking device, which holds both interconnected connectors in place.

Coupling elements designed as threaded elements comprise an outer threaded surface provided on the housing of the connector as well as a corresponding inner threaded surface provided on the inner side of the tubular element. If desired or required by standards, that the connection between the coupling elements can only be released by means of a tool, then the outer side of the tubular element is provided with a profile that can be grasped by a tool, e.g. a wrench.

In a preferred embodiment at least one snap-in pin is partially cut out of the tubular element. At the free end of the snap-in pin at least one coupling element preferably designed as a hook is provided, which can engage in a receiving opening provided in the housing of the connector.

In this manner a simple coupling device is achieved, which can easily be operated, in order to couple and release the tubular element to and from the connector. The snap-in pin can be worked into the tubular element by simply applying a U-formed cut and can therefore easily be released from the housing of the connector, e.g. by introducing a screwdriver into the cut and by lifting the snap-in pin.

According to the invention the interconnected connectors can be enclosed by one or two tubular elements. The connectors can be provided with lock elements that engage with one another as soon as the complementary connectors are interconnected and that prevent the connectors from getting automatically separated.

In order to allow disconnection of the locking elements, the tubular element of the first or the second connector or a common tubular element are provided with at least one access opening, into which a tool can be introduced, with which a lock element of the first and/or of the second connector can be actuated in order to release the connectors from one another.

A common tubular element can advantageously be used, which comprises at least a first coupling element corresponding to a coupling element of the first connector and at least a second coupling element corresponding to a coupling element of the second connector. The common tubular element serves therefore not only for protection against mechanical impacts but also as a locking device, which holds and secures two interconnected connectors in position. The common tubular element preferably comprises two snap-in pins having lock elements, which engage in receiving openings of the housing of the first or second connector respectively.

The common tubular element protects the connection between the first and the second connector particularly good. A frequently occurring mutual turning or bending of the two connectors, which can cause breakage of material or loosening of the connection, is thereby avoided.

Further, using a common tubular element advantageously allows protecting the contact zone of two interconnected connectors against intrusion of water. For this purpose, an O-ring seal can be provided for each connector within the common tubular element. The O-ring seal prevents water from intruding between the opposing front sides of the first and of the second connector.

In preferred embodiments, the housing of the connector comprises two side planes aligned in parallel to one another, on which side planes first and second guide ribs abut, which are arranged on the inner side of the tubular element aligned in parallel to its longitudinal axis. The guide ribs hold the connector torque proof in position so that it cannot be turned within the tubular element. Between the guide ribs, preferably an air channel is kept open, through which air can circulate in order to remove moisture and thermal energy.

In order to facilitate mounting of the tubular element preferably at least one catch element is provided within the tubular element, which prevents the housing from further moving thus fixing its position.

FIG. 1shows a first connector1A in the embodiment of a male connector with a related hollow cylindrical tubular element2A, which serves for receiving the first connector1A (seeFIG. 2).

The connector1A comprises an electrically insulating housing10A, which consists of two housing shells107A,108A, that are connected with one another e.g. by means of a clip- or snap connection. The housing10A comprises a centralised hollow cylindrical contact holder103A on its front side, through which a first opening in the housing101A leads into the interior space of the housing10A. In the interior space of the housing10A a contact element is provided, which extends along the contact holder103A and which is connected with an electrical cable3A, which is introduced through a second opening102A provided on the rear side of the housing10A.

Two tongue shaped lock elements104A, which extend in parallel to and enclose the hollow cylindrical contact holder103A in between, are connected in one piece with the housing10A and are provided on their front sides with wedge-shaped latch elements.

The housing10A of the first connector1A (the same applies to the housing10B of the second connector1B shown inFIG. 3) further comprises a flat upper side10osand a flat lower side10usarranged in parallel thereto. From each edge of the upper side10ostwo receiving openings105A (105B respectively) extend to the lower side of the housing10, which can fulfil various functions. If the connector1A is used without tubular element2A, ribbon like elements can be guided through the receiving openings105A, e.g. in order to fasten the connector1A. However, if the tubular element2A is mounted on the connector1A, then the receiving openings105A serve as coupling elements for holding the tubular element2A, which comprises thereto corresponding coupling elements215A, in a selected position. The corresponding coupling elements215A, which are shown inFIG. 1in a dashed line (see the corresponding coupling elements215B on the tubular element2B of the second connector1B inFIG. 5a), are provided on the interior side of the tubular element2A (2B respectively) on the lower side of the snap-in pin21A (21B respectively) facing the connector1A (1B respectively), which snap-in pin21A (21B respectively) having been laid open by means of a cut210A (210B respectively) extending in U-form in the tubular element2A (2B respectively). The length of the cut210A (210B respectively) is selected in such a way, that the snap-in pin21A (21B respectively) can be lifted by means of a tool as far as required to release the coupling elements215A,105A from one another.

The tubular element2A (the same applies for the second tubular element2B ofFIG. 3) comprises a simple structure and consists of a thin-walled hollow cylinder with an inner diameter, which preferably corresponds approximately to the largest cross diameter qd of the connector1A extending perpendicularly to the longitudinal axis x. The wall thickness wd of the tubular element2A lies preferably approximately in the range of ⅕ to 1/10 of the inner diameter. When using standard sizes of the connector, wall-thicknesses wd in the range of 0.5 mm to 2.5 mm are useful. However, the wall-thicknesses wd are selected depending on the expected mechanical impacts and under consideration of the applied materials. Furthermore, preferably enforcing elements, such as longitudinal ribs and/or cross ribs, are provided on the inner side and/or the outer side of the tubular element2A, with which the tubular element2ais enforced or stiffened. With the proposed materials, preferably thermoplastic casting resin preferably comprising Polyimide-Components and Siloxane-Copolymer-Components, very good protection can be achieved for the connector1A already with small dimensions of the tubular element2A. It must be noted, that the applied materials with the high resistance against mechanical impacts of the material used for the tubular element2A and the relatively high elasticity of the material used for the connector1A an optimal interaction is achieved. Thereby it is not required that the tubular element2A completely absorbs the energy of the mechanical impact. However it is important, that the energy of the mechanical impact, which is transferred from the tubular element2A to the housing10A of the connector1A, is reduced so far that the energy of a mechanical impact absorbed by the housing10A of the connector1A does not cause damage.

By this load sharing a significant improvement of all relevant properties of the connector1A can be achieved while applying small dimensions of the tubular element2A. In order to reach overall mechanical protection the length l2of the tubular element2A is preferably selected approximately corresponding to the length l1of the housing10A (without extremities103A,104A) of the connector1A.

FIG. 1further shows that inside the tubular element2A two pairs of guide ribs22A,23A are arranged, opposing one another, extending axially, and preferably comprising mounting slants231. The second pair of the guide ribs23A extends below the snap-in pin21A and is interrupted by the U-formed cut210A of the snap-in pin21A at a corresponding position. After the tubular element2A has been mounted, the guide ribs22A,23A abut the upper side10osor the lower side10usrespectively of the housing10A of the connector1A and hold the connector1AA torque proof and practically without play within the tubular element2A. The guide ribs22A,23A simultaneously serve for enforcing and stiffening the tubular element2A. Air channels26A are provided between the guide ribs22A,23A, through which air can circulate and can remove moisture and thermal energy.

FIG. 2shows the connector1A ofFIG. 1after it has been inserted into the tubular element2A. It can be seen that the housing10A of the connector1A, which is held on the front side by means of a catch element28A, is supported laterally by the tubular element2A and on the other and lower side by the guide ribs22A,23A provided on the inside of the tubular element2A. The extremities of the connector, namely the hollow cylindrical contact holder23A and the tongue shaped lock elements104A protrude on the front side out of the tubular element2A. The resulting connector1A, which is enforced with the tubular element2A, is only slightly larger than the connector1A without the thin-walled tubular element2A. However,FIG. 2shows that the connector1A that is enforced with the tubular element2A has a compact outer surface, which does not exhibit any weak points.

Further, between the guide ribs23A a clearance260A is provided, into which a tool, e.g. the blade of a screwdriver can be introduced against the front part of the snap-in pin21A, on which a wedge212A is provided. By introducing the tool on the front side the wedge212A and therefore the front part of the snap-in pin21A is pushed upwards, releasing the coupling elements215A provided on the front part out of the receiving openings105A to of the housing10A of the connector1A (see the corresponding embodiment of the tubular element2B provided for the second connector1B inFIGS. 5aand5c). However, without a corresponding tool the tubular element2A cannot be released from the housing10A of the connector1A.

FIG. 3shows a second connector1B in the embodiment of a bushing with a related hollow cylindrical tubular element2B, which serves for receiving the second connector18(seeFIG. 4).

The second connector1B comprises an electrically insulating housing10B, which consists of two housing shells1078,108B, which are connected with one another. The housing10B comprises on its front side a first opening that is forming a contact receiver1038, into which the contact holder103A of the first connector1A can be inserted. In the interior space of the housing108a contact element is provided, which is connected to an electrical cable3B that is introduced through a second opening1028that is provided on the rear side of the housing108.

Two lock elements104B are formed on the housing10B in the embodiment of lugs that are arranged in parallel enclosing the contact receiver103B in between. The lock elements104B serve for receiving the tongue shaped lock elements104A of the first connector1A.

As described above, the housing10B of the second connector1B also comprises a flat upper side10osand a flat lower side10usarranged in parallel thereto. From each edge of the upper side10osthree receiving openings105B extend to the lower side of the housing10, which serve i.a. as coupling elements for mounting the tubular element2B, which comprises a snap-in pin21B with corresponding coupling elements215B.

The second connector1B can therefore also be inserted up to a catch element28B provided in the second tubular element2B, so that the connector1B then abuts laterally the inner wall of the second tubular element2B and on the upper and the lower side the guide ribs22B,23B, between which air channels26B are provided. The tubular element2B can be released again, by lifting the snap-in pin21B of the second tubular element2B with the coupling elements215B out of the coupling elements105B, i.e. the coupling openings provided in the housing10B of the second connector1B, so that the tubular element2B can be removed. For this purpose, again the blade of a screwdriver can be introduced on the front side of the snap-in pin21B into a clearance260B against a wedge212B provided on the snap-in pin21B (seeFIGS. 5aand5c), in order to lift the front part of the snap-in pin21B.

FIG. 4shows that the second connector1B does not comprise extremities extending outside and is therefore with its front side arranged flush with the front side of the second tubular element2B. The extremities103A,104A of the first connector1A are therefore introduced into the second connector1B that is designed as bushing and therefore into the second tubular element2B. After the connection of the complementary connectors1A,1B, lock elements104A,104E of the connectors1A,1B are coupled or latched with one another and can therefore be released from one another only, if the second tubular element2B provides access to the lock elements104A,104B.

FIGS. 5a,5band5cshow that access openings24B can be provided in the second tubular element2B, through which a tool can be guided to the lock elements104A,104B, in order to release them from one another. For example, the tips of a forked gripper can be introduced into the access openings24B.

FIG. 5ashows the interior space of the cylindrical tubular element2bofFIG. 3. It is shown, that the guide ribs23A extend across the snap-in pin21B, which comprises the front part with the wedge212B and the coupling elements215B, which exhibit the form of hooks or cams that can be received by the openings105B in the housing10B of the second connector1B.

FIG. 5bshows schematically that a tubular element2can comprise a plurality of snap-in pins21B,21, so that two connectors1A,1B can be introduced into a common tubular element2. Since the coupling elements215of the snap-in pins21can engage in both connectors1A,1B, the common tubular element2therefore serves not only for protecting the inserted connectors1A,1B, which are held axially aligned, but also as a locking device, with which the two interconnected connectors1A,1B are held in position.

LITERATURE

[1] US2011294324A[2] US2010/0323554 A1[3] US2003100215A[4] US6011122A[5] US2004232598A1
List of References1A,1B first and second connector10A,10B housing of the connector1A,1B10osupper side of the housing10A,10810uslower side of the housing10A,10B101A,101B first opening in the housing10A,10B102A,102B second opening in the housing10A,108103A contact holder on the first connector1A1038contact receiver on the second connector1B104A lock element on the first connector1A104B lock element on the second connector1B105A,105coupling elements on the connector1A or1B106O-ring seal on the contact holder107A,107B first housing shell108A,108B second housing shell2common tubular element2A,2B first and second tubular element21snap-in pins of the common tubular element21A,218snap-in pin210A,210E cut to expose the snap-in pins21A,218212A,212B wedge215A,215B coupling elements on the snap-in pins21A,21B22A,22B first pair of guide ribs23A,23B second pair of guide ribs231mounting slant24B access openings26A,26B air channels between the guide ribs23A,23B260A,260B clearance28A,28B catch element3A,3B electrical cable