Abstract:
The invention relates to a plug connector system for a plug connection between electrical conductors, wherein the plug connector system accommodates plug modules with electrical contacts contained therein, wherein said plug modules are first inserted laterally into a region of a holding frame, wherein a plug insert is arranged in the same and locked in place, and then subsequently slid 90° sideways in the holding frame and held in place. The housing frame is designed as a self-supporting part of the plug connector system for the purpose of accommodating the plug modules, and can provide protection from external influences by means of a surrounding housing. 
     In addition, in contrast to conventional arrangements used to date in plug connectors, the plug modules can be inserted into the holding frames from both sides, meaning in the direction in which the connection is made, or also in the opposite direction, and can be removed again.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    This application is a continuation of U.S. application Ser. No. 13/514,700, filed Jun. 8, 2012, which was a nationalization of PCT/EP09/008780 filed Dec. 9, 2009 and published in German, hereby incorporated by reference. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    The invention relates to a plug connector system, consisting of a first holding frame which holds electrical terminals therein in separate plug modules, wherein the first holding frame is protected against external influences by means of a housing which surrounds the same. The plug connector system is provided for the purpose of establishing contact with plug modules held in a second holding frame. 
         [0004]    Such a plug connector system was conceptualized with the intention of simplifying the installation thereof, and to design plug connections having plug modules in a housing to the requirements of an industrial environment. 
         [0005]    2. Description of the Related Art 
         [0006]    A holding frame for plug connector modules is known from EP 0 860 906 B1, where said frame is intended for installation in plug connector housings and has a mounting frame consisting of two halves connected to each other by hinges. Plug connector modules can be inserted into said halves. 
         [0007]    In addition, a holding frame manufactured from plastic is known from U.S. Pat. No. 7,316,591 B2, wherein multiple plug modules arranged next to each other are held between wall segments divided by slots. 
         [0008]    A particular disadvantage of such known holding frames is that the same must always be inserted into a further housing and then screwed in, wherein care must be taken to consider the direction of current flow and therefore the direction in which the contacts inserted into the plug modules face, and that a prespecified direction of installation from the holding frame to the plug connector housing was always prespecified. 
       SUMMARY OF THE INVENTION 
       [0009]    The invention therefore addresses the problem of designing a plug connector housing structure which makes do without separate fastening means, and which enables the installation, from both the plug end and the connection end of each plug connector piece, of modules having terminals, wherein, also, in principle the direction of current flow is also not dependent on the design of the contact. 
         [0010]    This problem is addressed in that both the first holding frame and the second holding frame include a rectangular feedthrough opening, the same having devices for holding the plug modules, in that a plug insert is arranged in each of the rectangular feedthrough openings, wherein the plug modules are arranged such that the same can be inserted into the holding frame and can be fixed in the rectangular feedthrough opening, and in that the plug modules can be inserted into the rectangular feedthrough opening from both sides, meaning from the plug side as well as from the connection side. 
         [0011]    Advantageous embodiments of the invention are given in the dependent claims. 
         [0012]    The invention is a plug connector system which accommodates terminals contained in plug modules, wherein the plug modules are held in a holding frame such that they can be connected and can be released. While one of the holding frames is permanently built into a device supplied with the current, as a flange frame, a second holding frame is protected from external influences by a plug connector housing, and is able to be moved to be connected to the built-in holding frame by means of a corresponding electrical cable. However, independently of this design, a plug connection created by two cable plugs can also be contemplated. 
         [0013]    While in similar plug connector structures plug modules are initially held in a separate frame, and the frame must then be screwed into a further housing part provided for this purpose, the design according to the invention has a frame which can be used simultaneously as a holding frame and housing frame to hold the module, and/or can be connected to a plug connector housing. 
         [0014]    However, both holding frames have the same system for accommodating the plug modules inserted therein. 
         [0015]    For this purpose, each holding frame contains a plug insert which is fixed, on a side thereof, inside a rectangular feedthrough opening in the holding frame via corresponding locking- and abutment contours on three sides. 
         [0016]    In the U-shaped, angled side frame of the plug insert, molded tongues are incorporated both on the upper and lower edges thereof and the ends of the molded tongues are spaced apart and face into the rectangular feedthrough opening at an angle. 
         [0017]    The plug modules advantageously have longitudinal webs, and the module can initially be inserted into the holding frame between the tongues of the plug insert by means of said longitudinal webs, to then be pushed onto glide rails molded onto the side of the holding frame (molded thereon perpendicular to the line traveled during the insertion of the plug modules) by means of cross webs molded onto the modules. The rectangular recess is finally filled completely with plug modules. This insertion process is carried out with no tools. 
         [0018]    Because the plug modules inside a plug connection in the plug insert and in the holding frame must have a mirror-image configuration, each plug insert is designed in such a manner that the plug modules can only be inserted into the rectangular recesses when rotated about the axial dimension of the plug. 
         [0019]    It is additionally advantageous that the plug modules can also be inserted into each of the holding frames from both sides, meaning from both the normal plug side with the mating plug, and also from the cable connection side. 
         [0020]    An additional advantage of the plug insert according to the invention is that it also has devices to ensure a PE connection in the simplest manner, without tools—thereby connecting a protective line according to regulations. In one configuration, an electrical conductor can be connected to the plug insert in a plugable manner by means of a crimp connector; in another configuration, an electrical conductor, as a Litz conductor, can be plugged-in and establish a contact by means of an already disclosed device. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0021]    These and other objects of the invention, as well as many of the intended advantages thereof, will become more readily apparent when reference is made to the following description taken in conjunction with the accompanying drawings. 
           [0022]    One embodiment of the invention is illustrated in the figures, and is described in greater detail below, wherein: 
           [0023]      FIG. 1  shows a plug connector system in an exploded drawing, 
           [0024]      FIG. 2  shows a housing frame having a plug insert, 
           [0025]      FIG. 3   a  shows a corner cutaway view inside the housing frame, according to  FIG. 2 , 
           [0026]      FIG. 3   b  shows a corner cutaway view of the housing frame having a plug insert, according to  FIG. 2 , 
           [0027]      FIG. 4   a  shows two plug inserts arranged one on top of the other in perspective, 
           [0028]      FIG. 4   b  shows two side frames of the plug insert arranged one on top of the other, 
           [0029]      FIG. 4   c  shows a top view of the side frames of the plug inserts having plug modules in the inserted position, 
           [0030]      FIG. 5  shows a perspective illustration of a corner cutaway view of two housing frames which are arranged one on top of the other and which have two plug modules, 
           [0031]      FIG. 6  shows a perspective partial view of a housing frame having two alternative PE connector elements, 
           [0032]      FIG. 7  shows a perspective view of two plug modules, 
           [0033]      FIG. 8  shows a disassembly tool for plug modules, 
           [0034]      FIG. 9  shows a variant of plug modules, and 
           [0035]      FIG. 10  shows a top view of a holding frame having a plug module and a coding using a pentaprism. 
       
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0036]    Further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description. 
         [0037]      FIG. 1  shows a plug connector system in an exploded spatial drawing, having a plug connector housing  3 , a first housing frame  10 , and a second housing frame  20  designed as a flange frame. 
         [0038]    The housing frame is designed as a self-supporting first holding frame  10 , and has, among other things, a locking unit  4  integrated into the housing frame, wherein the mechanism of the locking unit [ 4 ] is released by means of a pushdial configuration. Multiple plug modules  40  are arranged inside a rectangular feedthrough opening  11  of the holding frame  10 , and correlate with plug modules  40 ′ of a second holding frame  20  which matches the rectangular feedthrough opening [ 11 ]. 
         [0039]    In this case, the flange frame is installed on or in, and fixed to, any assembly, including a motor housing or circuit box housing, for example, and the mobile plug connector system, having the housing frame (holding frame  10 ), is connected to the fixed flange frame (of the second holding frame  20 ). 
         [0040]    Each of the holding frames  10 ,  20  is designed for the plug modules  40 ,  40 ′ to be inserted therein, and has corresponding contours for installation in the semicircular plug connector housing  3  or for a section of a housing. 
         [0041]    However, the flange frame designed as the second holding frame  20  has a flange  22  around the periphery thereof, wherein said flange [ 22 ] has a collar in which a seal ring  23  is arranged, the same running around the periphery of the collar, for the purpose of securely sealing the Plug connection against external influences. The plug end  6  and the connection end  7  on the side of the cable are also indicated. 
         [0042]    In  FIG. 2 , the holding frame  20  of the plug connector system is shown, along with its noticeable rectangular feedthrough opening  11 , inside the flange  22  running around the periphery thereof, and having a plug insert inserted into the holding frame [ 20 ]. 
         [0043]    In this case the plug insert  30  is snapped into the holding frame in one of the narrow side regions, as a U-shaped component with side frames  31  bent at right angles. 
         [0044]      FIG. 3   a  shows a corner cutaway view of the holding frame  20 , viewed from the plug side  6 . 
         [0045]    The cutaway view shows multiple molded components which are responsible for the insertion of a plug insert  30  as well as for the functionality of the system. 
         [0046]    Similarly, a partially free-standing pin  26  is shown, the same having a polarizing rail  26 ′, as well as a recess  29  and a square projection  13 . 
         [0047]      FIG. 3   b  shows the same cutaway view inside the rectangular feedthrough opening, with the plug insert  30  designed as an electrically conducting part which is held by means of the mounting link  33  and the pin  26 . The plug insert  30  in this case is inserted into the rectangular feedthrough opening  21  from above from the plug side  6 . 
         [0048]    In this case, the plug insert  30  is pushed on the corner regions thereof behind each of the molded pins  26 , and at the same time is held by means of a mounting link  33 , the same engaging in recesses  29  in the holding frame  20 , such that the configuration prevents further displacement of the plug insert  30 . 
         [0049]      FIG. 4   a  shows two plug inserts  30 ,  30 ′ in a perspective view, wherein the same are arranged in a connected system in the holding frame  10 ,  20 . Here, the plug insert  30 ′ differs only by being a mirror-image object. 
         [0050]    Two tongues  34  which are oriented toward the inside from the upper and the lower edge  32  of the frame are molded in the side frames  31 , wherein the tongue ends  35  thereof are spaced apart from each other in the interior space of the rectangular feedthrough opening  11 . 
         [0051]    The molded projection  13  with a rounded square shape on the long sides of the holding frame  20 —and this applies as well for the first holding frame  10 —which projecting into the center of the tongues  34  of the side frame  31 , effectively constitutes a limit for the four tongue ends  35  of the plug insert  30 ,  30 ′, and is at the same time the center of rotation for the perpendicular-to-horizontal sliding that takes place inside the holding frame  10  or  20 , following the insertion of the plug module  40 . 
         [0052]    In addition, the configuration also includes contact links  37  in a wave-shaped construction at least on one side of the plug insert  30 ,  30 ′, and these contact links [ 37 ] contact their respective opposite plug insert when the two housing frames  10 ,  20  are connected. 
         [0053]    As can be seen in  FIG. 4   b , the tongues  34  are arranged in the side frames  31  of the plug inserts  30 ,  30 ′ for both of the holding frames  10 ,  20  in such a manner that the side frame  31  shown above in this figure shows a polarization slot  39  on its outer side (which is exactly as wide as the central slot  39 ′), while on the lower side frame  31  the polarization slot  39  is arranged on the inside near the corner. Longitudinal webs  45  molded onto the narrow sides of a plug module  40  are inserted into both of the slots  39 ,  39 ′. 
         [0054]    In addition,  FIG. 4   c  shows how the longitudinal webs  45  and the cross webs  43  engage from the plug modules  40  into the side frames  31  of both plug inserts  30 ,  30 ′, Each of the plug modules  40  has short longitudinal webs  45  on the edges of the narrow sides  41 , as well as two cross webs  43  approximately in the middle of the narrow side, wherein said cross webs [ 43 ] are spaced apart by a groove  44 . 
         [0055]    To assemble the two holding frames  10 ,  20 , the plug modules  40  are initially inserted and guided perpendicular to the respective holding frame, in the region of the plug insert  30 , by means of the longitudinal webs  45 , for the purpose of then being pushed, by means of the cross webs  43  and/or the groove.  44  arranged between the former, on two glide rails  14 ,  14 ′ and  24 ,  24 ′ molded onto the inside of the holding frames  10 ,  20  on opposite sides, until the plug modules [ 40 ] reach a stop in the rectangular feedthrough opening  11 ,  21 . 
         [0056]    The engagement of the longitudinal webs  45  between the tongues  34  and the polarizing slots  39 ,  39 ′ initially ensures the possibility of the inserted plug modules  40  being polarized with no chance of confusion. In this case, the longitudinal webs  45  are molded onto the narrow sides  41  of the plug modules  40 ,  40 ′ asymmetrically with respect to the width of the module housing, wherein the plug modules [ 40 ,  40 ′] are, in principle, similar or identical. 
         [0057]    Moreover, for the purpose of making the connection polarity unmistakable, one of the pins  16 ,  26  in the holding frame  10 ,  20  is configured with an additional polarization rail  16 ′,  26 ′ which is molded onto the holding frame [ 1   0 ,  20 ] and Which prevents an incorrect connection because the region of the plug module  40 ,  40 ′ intended for this region of the holding frame [ 10 ,  20 ] has a narrower construction than on the opposite side. On said opposite side, the pin  16 ,  26  does not have an additional molded rail (see  FIG. 3   b  as well). In addition,  FIG. 10  shows that the lengths of the glide rails  24 ,  24 ′, for example, are different, such that only the narrower side of a plug module can be inserted into the corresponding recess between the pin  26  and the longer glide rail  24 . In this way, the configuration ensures that two plug modules arranged opposite one another in mutually connected holding frames cannot be connected in any other way which would lead to destruction of components or systems. 
         [0058]      FIG. 5  shows a perspective view and a partial cutaway view of the holding frames  10 ,  20 , wherein two plug modules  40 ,  40 ′ are inserted into the two holding frames and rotated laterally by 180° to each other. In this case, one of the side frames of the plug inserts is not shown. 
         [0059]    The longitudinal webs  45  on the narrow sides  41  of the plug modules  40 ,  40 ′, each being offset, are clearly visible. 
         [0060]    In addition, the figure shows how the plug module  40  can be pushed horizontally on the glide rails  14 ,  14 ′ or  24 ,  24 ′ after the plug module [ 40 ] has been inserted perpendicularly by means of the groove  44  and the cross webs  43  which divide the same. In order to transmit or to continue the protective function of a prescribed protective line inside the plug connector, a special connection for the protective line is configured on each of the plug inserts  30 , as indicated in  FIG. 6 . 
         [0061]    In this configuration, the possibility exists of connecting a crimp contact  56  to a corresponding electrical conductor, and to insert this crimp contact  56  into a square recess  17  in the holding frame  10 , for example, and to establish contact with the plug insert  30  by means of two contact tongues  38  which curve off of the crimp contact [ 56 ] in a U shape. 
         [0062]    On the other hand, a further, rectangular recess  18  is included in the holding frame  10 , wherein a known connector element  58  having a separate function is inserted into this rectangular recess [ 18 ], and is provided for establishing contact with electrical conductors known as Litz conductors. 
         [0063]    Also for this purpose, two U-shaped contact tongues  38 ′ are configured on the plug insert  30 , and reach into the connector element  58  for the purpose of establishing a contact. Both connections made to establish the PE contact are realized via the cable connection side  7  of the first holding frame  10  as well as the second holding frame  20 , wherein the latter is not further displayed. 
         [0064]      FIG. 7  shows an example of two plug modules  40 ,  40 ′, wherein a first plug module  40  contains pin terminals  55 , and a second plug module  40 ′ (not visible) contains socket contacts. In this case, the second plug module  40 ′ having the socket contacts is configured with a collar  47  which can be inserted into a corresponding recess  48  of the first plug module  40 , for the purpose of establishing a contact with the pin contacts  55 . In addition, in one possible variant, both plug modules are equipped with pin or socket contacts, and a separately manufactured adapter is likewise designed like a collar which is snapped onto and locks with one of the plug modules  40 . For this purpose, then, this adapter is configured with contacts that are complementary to the contacts in each of the plug modules. 
         [0065]    A yoke-shaped disassembly tool  50 , as shown in  FIG. 8 , is necessary to remove one or more plug modules  40  from one of the holding frames  10 ,  20 . The side brackets  52  of the disassembly tool [ 50 ] which are angled parallel to the narrow sides  41  of the plug modules  40 ,  40 ′ are slid over the narrow sides of the plug module  40 ,  40 ′, the same being inserted in the plug insert  30 . 
         [0066]    In this case, the tongues  34  on the plug insert  30  are bent outward, such that the latch they have with the cross webs  43  of the plug module  40 ,  40 ′ is released, and the module can be removed from the plug insert  30  and therefore from the respective holding frame. 
         [0067]    The neighboring plug module  40  must first be slid laterally in the region of the plug insert  30  before the latch of the tongues  34  can be released by means of the disassembly tool  50 . 
         [0068]    Also, according to the configuration, the plug modules can be pulled out of their frame on either side. 
         [0069]    That is, in the direction  6  in which the connection is made, or in the opposite direction of the connection side  7  of the holding frame  10 ,  20 . 
         [0070]    In addition, in a second embodiment, a plug module  40 ″ as shown in  FIG. 9  is not intended to be able to slide laterally within the holding frame  10 ,  20 , for particular applications, wherein the plug module [ 40 ″] is only inserted in the region of the plug insert  30  either in or against the direction in which the connection is made. 
         [0071]    For this purpose, the two cross webs  43  have been merged together into one cross web  43 ′ on the narrow side of the module, such that no groove is available for guiding a sliding motion onto the glide rails  14 ,  14 ′,  24 ,  24 ′. 
         [0072]    In addition, in both of the holding frames  10 ,  20  of this plug connection, a mechanical coding is included using two pentaprism posts, for the purpose of providing a differentiating feature for correct connections in cases where a number of similar plug connector housings are connected together. 
         [0073]    For this purpose, at least one 5-sided coding post  60  is configured in each holding frame  10 ,  20  on the plug side thereof, as shown in  FIG. 10 , and each of these coding posts [ 60 ] is divided in half through the center thereof, and can be plugged into a particular matching (or even non-matching) opposite recess, such that only the matching recess positions allow connection of the two housing parts. 
         [0074]    In this case, number symbols are included for the different recess positions, which are numbered with the digits 0-4 for the first posts, and 5-9 for the second posts in the 2-part coding system provided here. In this way, up to 25 combinations are possible. 
         [0075]    In addition, the top view of the holding frame  20  designed as a flange frame also illustrates a plug insert  30  having a plug module  40  inserted into the same. 
         [0076]    The invention being thus described, it will be apparent that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be recognized by one skilled in the art are intended to be included within the scope of the following claims. 
       List of Reference Numbers  
       [0000]    
       
           1  plug connector system 
         
           2 
         
           3  housing 
           4  latching/locking mechanism 
         
           5 
         
           6  plug side 
           7  connection side 
         
           8 
         
         
           9 
         
           10  housing frame, holding frame  1   
           11  rectangular feedthrough opening 
           12  recess for  33   
           13  projection 
           14 ,  14 ′ glide rail, long horizontal;  14 ′ glide rail, short 
           15  longitudinal bar with 
           16 ,  16 ′ (pin;  16 ′ polarization rail) 
           17  recess, crimp contact 
           18  recess, easy lock, for Litz conductor 
         
           19 
         
           20  flange frame, holding frame  2   
           21  rectangular feedthrough opening 
           22  peripheral flange 
           23  peripheral seal ring 
           24 ,  24 ′ glide rail, horizontal;  24 ′ opposite, short 
           25  opening for screw connection 
           26 ,  26 ′ pin;  26 ′ polarization rail. 
           27  recess, crimp contact, PE 
           28  recess for (easy lock) for Litz conductor, PE 
           29  recess for  33   
           30 ,  30 ′ plug insert (locking element), U-shaped.;  30 ′ opposite plug insert, flange 
           31  side frame, 
           32  upper and lower edge 
           33  mounting links 
           34  tongues 
           35  tongue ends 
           36  angled latch (not mentioned) 
           37  contact latch, wave-shaped 
           38 ,  38 ′ contact tongues for PE conductor, U-shaped, 
           39 ,  39 ′ polarization slot;  39 ′ central slot 
           40 ,  40 ′ plug module;  40 ′ second plug module,  40 ″ variant 
           41  narrow sides 
           42  long sides 
           43 ,  43 ′ 2 narrow cross webs;  43 ′ a wide cross web 
           44  groove 
           45  longitudinal webs 
         
           46 
         
           47  collar 
           48  recess for  47   
         
           49 
         
           50  disassembly tool 
           51  U-shaped bracket 
           52  side bracket, slotted longitudinally 
         
           53 
         
           55  pin contacts 
           56  crimp contact for PE 
         
           57 
         
           58  contact element for FE. 
         
           59 
         
           60  coding posts