Electrical connector

An electrical connector comprises a first connector element (2) and a second connector element (4) carrying respective contacts, and interconnected so as to be movable, along a coupling direction, between an uncoupled state and a coupled state. A sliding element (5) is mounted in the first connector element (2) so as to be slidable, in a direction orthogonal to said direction of coupling, between an extended position and a retracted position in the first connector element (2). The sliding element (5) has one or more cam tracks (5T), each engaged by an element (4P) of the second connector element (4) in such a way that a movement of the sliding element (5) from the extended position thereof to the retracted position thereof in said first connector element (2) causes the second connector element (4) to move into the coupled state. Each of said cam follower elements (4P) of the second connector element (4) engages the respective cam track (5T) via a cog (4W) mounted rotatably on said cam follower element (4P).

The present invention relates to electrical connectors of the type comprising a first connector element and a second connector element carrying respective contacts and interconnected so is to be movable, along a coupling direction, between an uncoupled state and a coupled state, the connector further comprising a sliding element mounted in the first connector element so as to be slidable, in a direction orthogonal to said direction of coupling, between an extended position and a retracted position in said first connector element, said sliding element having one or more cam tracks, each engaged by an element of said second connector element in such a way that a movement of the sliding element from the extended position thereof to the retracted position thereof in said first connector element causes the second connector element to move into the coupled state.

The object of the present invention is to provide a connector of the above-mentioned type in which the force which has to be applied to the sliding element in order to couple the two connector elements is substantially reduced compared to that required with known connectors of the above-mentioned type.

A further object of the invention is to provide a connector of the above-mentioned type which is no more complicated or expensive to produce compared to known connectors.

Yet a further object of the invention is to provide a connector which is compact in size.

With a view to achieving these and further objects, the invention relates to a connector having all the features indicated at the outset of the present description and further characterised in that each of said pins of the second connector element engages the respective cam track via a rolling element mounted rotatably on the pin.

As a result of the above feature, the sliding element and the pins of the second connector element are contacted with rolling friction instead of with sliding friction, which makes it possible to substantially reduce the force to be applied to the sliding element in order to close the connector.

In accordance with a further preferred feature, the surface of each rolling element and the cooperating surface of the respective cam track are knurled or toothed so as to avoid, or at least minimise the risk that the rolling element may slip on the track during the movement to close the connector. It is thus ensured that the movement of the rolling element is substantially a purely rolling movement.

In the drawings, reference numeral1denotes, as a whole, a high-voltage electrical connector which can be used, for example, for connection to the battery powering an electric traction motor for an electric traction motor vehicle. It should be noted that although the invention is illustrated in this instance with reference to such a specific application, it may nonetheless be used with any other type of connector which has a sliding element for controlling closure of the connector.

The connector1comprises a first connector element2, which can be seen separately inFIGS. 11A and 11B, having a box-like body which is made of plastics materials and downwardly open with an upper wall2U, a front wall2F, a rear wall2R and two side walls2S. The body of the first connector element2further includes a central core2C defining five prismatic tubular bodies2T projecting from the upper wall2U and extending as far as the base of the body of the connector element2so as to define a peripheral receptacle2L between the central core2C and the walls2F,2R,2S of the body of the connector element2(seeFIG. 11B). The prismatic tubular elements2T receive the same number of contacts (not visible in the drawings) of any type known per se with five conductors3arranged at the ends thereof. The contacts are not shown in the drawings provided, both because (as mentioned above) they may be of any known type and also because they themselves are not the subject of the present invention.

The connector1further comprises a second connector element4which can be seen separately inFIG. 9. The connector4has a body made of plastics material incorporating a base plate4B from which a box-like body projects upwardly and includes two spaced, parallel side walls4S and two spaced, parallel end walls4E. Prismatic tubular elements4T which receive the respective electrical contacts of any known type, adapted for coupling to the electrical contacts carried by the first connector element2extend upwardly within the space defined by the walls4S,4E. The contacts of the element4are also not shown in the drawings, both because (as mentioned above) they may be of any known type and also because they themselves are not the subject of the present invention.

As can be seen clearly inFIGS. 1A,9and10, three horizontal pins4P, on which three rolling elements, specifically three cogs4W made of metal or plastics material are rotatably mounted, project from the outer face of the two side walls4S. As can be seen inFIG. 10, each pin4P has a diametrical slot4F which defines two resiliently deformable half-pins, of which the head is provided with projections4G which axially retain the respective cog4W once is it has been clicked onto the pin4P. In the preferred embodiment shown in this instance, each cog4W has a toothed rolling surface.

The substantially tubular body defined by the walls4S,4E of the second connector element4is slidingly received in the peripheral receptacle2L of the first connector element2.

Furthermore, as can be seen in the drawings and, in particular, inFIG. 1, the inner faces of the two side walls2S of the first connector element slidingly guide the side walls5S of a substantially U-shaped sliding element5with a front wall5F (seeFIG. 7). The sliding element5is slidingly mounted between the two side walls2S of the first connector element2between an extended position (for example shown inFIG. 1and inFIG. 3) and a retracted position (shown inFIG. 2and inFIG. 6).

As can be seen inFIGS. 7 and 8, the inner surface of each of the two side walls5S of the sliding element5is formed with three grooves5F, each of which receives a respective cog4W carried by the second connector element4. Each groove5F is downwardly delimited by a generally planar, inclined surface which defines a track5T for the respective cog4W. In the preferred embodiment, the generally planar, inclined surface of each track5T is toothed and cooperates with the toothed rolling surface of the respective cog4W in such a way that when the sliding element is brought out of the extended position shown inFIG. 1, in which the front wall5F is spaced from the front wall2F of the first connector element2, and into the retracted position shown inFIG. 2, in which the front walls5F,2F are drawn together, the tracks5T act as cam tracks which force the second connector element to be raised until arranged in the state coupled to the first connector element, in which the respective electrical contacts are coupled, whilst the cogs4W carried by the second connector element4are forced to rotate along the tracks5T in the sliding member5.

As a result of the pre-arrangement of the rolling elements4W on the pins4P of the second connector element4, the sliding element5and the second connector element4are engaged with rolling friction, which makes it possible to drastically reduce the force for closing the connector required in order to mutually couple the contacts carried by the two connector elements2,4.

Each of the grooves5C formed in the inner face of the walls5S of the sliding element5is wider than the diameter of the respective cog4W so as to ensure that each cog4W rolls on the respective track5T without contacting the opposite side of the respective groove5C.

In the specific embodiment illustrated, the movement of the sliding element5from its extended position to its withdrawn position for closing the connector is assisted by an actuation lever6. The lever6has a substantially U-shaped plastics material body with a central crossbar6C which connects two side arms6S. In the vicinity of their free ends, the side arms6S have two projecting pins6A,6B facing their inner surfaces which engage with respective slots2A,2B penetrating the two side walls2S of the body of the first connector element2(see in particularFIGS. 3-6). The slot2A is curved, whereas the slot2B is straight and orientated in the direction of movement of the sliding element5. Furthermore, the pins6B of the lever6project inside the respective walls2S and engage two respective seats5P formed in the outer faces of the side walls5S of the sliding element5(seeFIG. 7). As a result of this arrangement, the movement of the lever6from the position shown inFIG. 3to the position shown inFIG. 6, through the positions shown inFIGS. 4 and 5, causes the progressive movement of the sliding element2from its fully extended position to its fully retracted position.

Of course, in accordance with the invention the prearrangement of a lever of the type illustrated is not essential and is generally only preferred when the force for closing the connector is substantially greater than usual levels. Normally, the prearrangement of the lever is not necessary owing to the reduction in the closure force obtained by the use of the rolling elements4W.

With reference again toFIGS. 1,2,12and13, the front wall5F of the sliding element5is provided on its upper edge with a button7for securing the connector in the closed state. The button7(seeFIG. 13) is received in a seat formed in the upper edge of the front wall5F and is slidingly mounted vertically in said wall between a deactivated, raised position and an activated, lowered position in which it is received in a respective seat7F formed in the front wall2F of the first connector element2.

In order to safeguard against the undesired opening of the connector, teeth5D carrying resilient arms (one of which can be seen inFIGS. 1 and 13) are formed in the side walls5S of the sliding element and, once the sliding element5has been brought into the retracted state, prevent it from returning to the fully extended position by engagement with stop surfaces (not shown in the drawings) formed in the side walls2S of the first connector element2. If it is desired to move the sliding element5into its fully extended position, it is necessary to use a tool T (shown inFIG. 14) having a grip H which extends from a base plate B which can be positioned above the sliding element5when said sliding element is only partly extended, the teeth5D contacting said stop surfaces. In this state, two prismatic pegs P projecting downwardly from the base plate B (seeFIG. 14) are received in respective seats S (FIGS. 1B and 13) in the body2and engage with the outwardly turned faces of the resilient arms carrying the teeth5D so as to deform them inwardly and allow the sliding element to move into the end position shown inFIG. 1B, corresponding to the connector being open, defined by the engagement of the pins6B carried by the lever6against the ends of the respective slots2B formed in the body of the first connector element2.

Naturally, the principle of the invention remaining the same, the forms of embodiment and details of construction may be varied widely with respect to those described and illustrated, which have been given purely by way of example, without thereby departing from the scope of the present invention.