Patent Publication Number: US-11387591-B2

Title: Plug connector module for an industrial plug connector

Description:
BACKGROUND 
     Technical Field 
     The disclosure relates to a plug connector module for an industrial plug connector and a method for fitting a holding frame with one or more plug connector modules. 
     Description of the Related Art 
     Plug connector modules are required as a constituent part of a plug connector modular system in order to be able to match a plug connector, in particular a heavy-duty industrial plug connector, to specific requirements in respect of signal and power transmission, for example between two electrical devices, in a flexible manner. To this end, plug connector modules are usually inserted into appropriate holding frames, which are also referred to as articulated frames, module frames or modular frames, amongst others. Therefore, the holding frames serve to receive a plurality of plug connector modules which are similar to one another and/or also different and to securely fasten said plug connector modules to a surface and/or a device wall and/or in a plug connector housing or the like. 
     In general, the plug connector modules each have a substantially cuboidal insulating body or a cuboidal housing. These insulating bodies or housings can serve, for example, as contact carriers and receive and fix contacts of very different kinds. The functioning of a plug connector formed in this way is therefore highly flexible. For example, pneumatic modules, optical modules, modules for transmitting electrical energy and/or electrical analog and/or digital signals can be received in the respective insulating body or housing and therefore used in the plug connector modular system. Plug connector modules increasingly perform measurement- and data-related tasks too. 
     Holding frames which are formed from two frame halves which are connected to one another in an articulated manner are optimally used. The plug connector modules are provided with approximately rectangular holder means or devices which project from the narrow sides. Recesses or openings which are designed as openings that are closed on all sides and which the holder means or devices enter when the plug connector modules are inserted into the holding frame are provided in the side parts of the frame halves. So-called articulated frames are used most frequently. For the purpose of inserting the plug connector modules, the holding frame  1  is folded open, i.e., opened, wherein the frame halves are folded open about the articulations only to such an extent that the plug connector modules can be inserted. The frame halves are then folded together, i.e., the holding frame is closed, wherein the holder means or devices enter the recesses and create secure, interlocking holding of the plug connector modules in the holding frame. 
     The above-described modular industrial plug connectors provide a high degree of flexibility and can be configured for a very wide variety of fields of use by way of plug connector modules with different functions being installed together in a common holding frame. However, the number of plug connector module spaces in a holding frame is limited. As a result, the flexibility of an industrial plug connector of this kind is limited. 
     The German Patent and Trade Mark Office has searched the following prior art in the priority application relating to the present application: 
     DE 10 2017 123 331 B3, DE 10 2014 108 847 A1 and DE 202 14 132 U1. 
     BRIEF SUMMARY 
     According to embodiments of the invention, a plug connector module is provided which expands the spectrum of use of an industrial plug connector. 
     The plug connector module according to embodiments of the invention is intended for use in a modular industrial plug connector. In this case, a plurality of similar and/or different plug connector modules are generally installed in a so-called holding frame. The holding frame is then subsequently installed in a plug connector housing or a device wall. The plug connector module according to embodiments of the invention is formed from at least two independent functional units. 
     A functional unit forms an independent component. This means that the functional unit can function independently, that is to say without a further functional unit connected to it. A functional unit is not rendered technically usable just by joining together two or more functional units to form a plug connector module. 
     A functional unit advantageously has at least one contact element and/or one sensor and/or one edge computer. The edge computer can collect, store, process and transmit data for example. The contact element may be, for example, an electrical contact element for power or signal transmission. The contact element may also be an optical contact element to which, for example, an optical waveguide is connected. A functional unit can have a plurality of contact elements, in particular also a plurality of different contact elements. For example, electrical and optical contact elements can be mixed with one another. The sensor may be, for example, a current sensor which monitors an adjacent contact element, for example arranged in an adjacent functional unit. However, temperature sensors, optical sensors, in particular scattered light sensors or other sensors, can also be provided. A functional unit can also contain a plurality of sensors, in particular also different sensors. A functional unit can also contain a sensor or a plurality of sensors and at the same time a contact element or a plurality of contact elements. 
     The functional units of a plug connector module can operate entirely independently of one another. However, the functional units may also experience a synergy effect due to the joining, in particular when sensors of one functional unit are combined with contact elements of another functional unit. 
     In an advantageous development of the invention, the plug connector module comprises or consists of a first functional unit and at least one second functional unit, wherein the first functional unit has another type of contact elements and/or a different number of contact elements and/or contact elements with a different cable connection technique to the second functional unit. For example, solid contact elements for transmitting power, for example for an electric motor, can be provided in a first functional unit. More delicate contact elements for signal transmission, for example for controlling said electric motor, can be present in the second functional unit which is connected to the first functional unit. The contact elements of the first functional unit can be electrically connectable to a conductor of a connected cable, for example using the so-called crimping technique. The contact elements of the second functional unit can be equipped, for example, with a so-called screw connection. In this way, different cable connection techniques can be realized within one plug connector module. 
     The individual functional units can be welded or adhesively bonded to one another to form a plug connector module for example. However, it is advantageous when a fastening means or device is integrally formed on the side wall of the functional unit, by way of which fastening means or device a first functional unit and a second functional unit can be reversibly fixed to one another. As a result, the functional units can be combined with one another in a simple manner and possibly also reused. 
     Advantageously, a first fastening means or device is integrally formed on a side wall of the first functional unit and a second fastening means or device is integrally formed on a side wall of the second functional unit, wherein the first and the second fastening means or devices are configured in a complementary manner to one another. As a result, reliable and primarily tool-free assembly of the plug connector module can be ensured. The contours of the fastening mean(s) or devices can be designed differently, so that only specific functional units can be combined with one another. For example, it makes no sense to combine an optical sensor of a first functional unit with an electrical contact element of a second functional unit. As a result, faulty assembly of a plug connector module can be pre-emptively prevented. 
     The functional unit may include a holder means or device on a side wall thereof for fixing the plug connector module in a holding frame. The holding frame which is completely fitted with plug connector modules can be installed in an industrial plug connector. In general, a first functional unit has a first holder means or device on a side wall and a second functional unit has a second holder means or device on a side wall. The holder means or devices then engage in corresponding openings of a holding frame, for fixing the plug connector module in the holding frame, as already described above. 
     The fastening means or devices and the holder means or devices are arranged on opposite side walls of the functional unit. The first and the second holder means or devices may have a different geometry. The openings in the holding frame are matched to the respective geometry. As a result, the orientation of the plug connector module, the so-called polarization, is defined. This measure facilitates the assembly of an industrial plug connector comprising the plug connector modules according to embodiments of the invention. 
     In a particularly advantageous embodiment of the invention, the plug connector module has a shielding element, wherein the shielding element, for electromagnetic shielding, is arranged between two adjacent functional units. The shielding element is formed from a metal material, in particular a sheet metal. If, for example, signal contact elements are arranged in the functional units, so-called crosstalk of the signal contact elements is prevented by the shielding. As a result, the plug connector module provides good signal integrity. 
     The plug connector module may also include a strain-relief element. The strain-relief element prevents excessively high transverse forces acting on the plug connector module, as a result of which the functional units could otherwise be torn apart. The strain-relief element can be arranged between two adjacent functional units and can form a functional unit with the shielding element for example. 
     The way in which a holding frame is fitted with a plug connector module according to embodiments of the invention is described below: 
     First, a first functional unit is combined with at least one second functional unit to form a plug connector module. The plug connector modules produced in this way can then be inserted into a holding frame. If the holding frame is a so-called articulated frame, the frame halves of the holding frame are folded open and the combined plug connector module is then inserted between the frame halves. This process can be repeated until the capacity of the holding frame for receiving plug connector modules is exhausted. However, insertion spaces can also remain free in a holding frame in order to be able to possibly retrofit yet further plug connector modules later if, for example, a machine is technically upgraded. Plug connector modules which are constructed from functional units can be used when fitting the holding frame. However, commercially available plug connector modules which do not consist of functional units of this kind can also be used. Depending on the proportion of holding frames which comprise plug connector modules consisting of functional units, the first method step “combining” has to be carried out n times. The method step “inserting” takes place m times analogously to the total number of plug connector modules. The numbers n and m originate from the set of natural numbers, wherein n is less than or equal to m. 
     Openings are respectively provided in the respective frame halves, the holder means or devices of the plug connector module(s) entering said openings during insertion. When the frame halves are folded together, the holder means or devices enter the openings completely, as a result of which interlocking holding of the plug connector module or of the plug connector modules in the holding frame is produced. 
     Conductors of a generally multi-core cable are respectively connected to the individual plug connector modules. After the holding frame has been fitted with a desired number of plug connector modules, said holding frame is installed in a plug connector housing of an industrial plug connector. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
       Embodiments of the invention are illustrated in the drawings and will be explained in more detail below. In the drawings: 
         FIG. 1  shows a perspective illustration of a plug connector housing of an industrial plug connector, 
         FIG. 2  shows a perspective illustration of a holding frame which is fitted with various plug connector modules, 
         FIG. 3  shows a perspective and partially transparent illustration of a first exemplary embodiment of a plug connector module according to the invention, 
         FIG. 4  shows a side view of two functional units which, when combined, form the first exemplary embodiment of the plug connector module according to embodiments of the invention, 
         FIG. 5  shows a side view of a second exemplary embodiment of the plug connector module according to the invention, 
         FIG. 6  shows a plan view of the second exemplary embodiment of the plug connector module according to the invention, 
         FIG. 7  shows a perspective illustration of a third exemplary embodiment of the plug connector module according to the invention, 
         FIGS. 8-15  each show two functional units which, when combined, form further exemplary embodiments of the plug connector module according to the invention, 
         FIG. 16  shows a connecting means or devices for two functional units, and 
         FIGS. 17 and 18  each show two functional units which, when combined, form further exemplary embodiments of the plug connector module according to the invention. 
     
    
    
     The figures may contain partially simplified, schematic illustrations. In some cases, identical reference signs are used for similar, but not necessarily identical, elements. Various views of similar elements may be shown at different scales. 
     DETAILED DESCRIPTION 
       FIG. 1  shows a plug connector housing  1  of an industrial plug connector. The plug connector housing  1  generally consists of a metal material and is produced, in particular, using a zinc die-casting process. A plug connector housing  1  of this kind is robust and has good electromagnetic shielding properties and is therefore particularly suitable for harsh industrial environments. 
       FIG. 2  shows a holding frame  2  which is fitted with various plug connector modules  5 ,  5 ′. The holding frame  2  has a frame-like design and has screws  4  at each of its corner regions. The plug connector housing  1  has an approximately rectangular cross section and has corresponding threaded bores  3  in the corner regions of the housing interior. The holding frame  2  can be fastened in the plug connector housing  1  by way of the screws  4 , in interaction with the associated threaded bores  3 . 
       FIGS. 3 and 4  show a first embodiment of a plug connector module  5  according to the invention. The plug connector module  5  consists of two functional units  6 ,  6 ′ which are reversibly connected to one another. The functional units  6 ,  6 ′ butt at a plane parallel to the plugging direction SR of the plug connector module  5 . The functional units  6 ,  6 ′ according to this embodiment of the invention produce transverse division of the plug connector module  5 . Each functional unit  6 ,  6 ′ functions independently with respect to its transmission properties and/or sensor properties. This means that the first sensor unit  6  can transmit, for example, power, data and/or signals, without being connected to the second functional unit  6 ′. This is also the case the other way around. 
     Contact elements and/or sensors (not shown for reasons of illustration), in any desired number in each case, are respectively arranged in the individual functional units  6 ,  6 ′. A first fastening means or device  7  is integrally formed on a side wall of the first functional unit  6 . A matching second fastening means or device  7 ′ is integrally formed on a side wall of the second functional unit  6 ′. The first and the second fastening means  7 ,  7 ′ are configured in a complementary manner to one another. In the exemplary embodiment shown here, fastening means or devices  7 ,  7 ′ are respectively integrally formed on two opposite side walls of the respective functional units  6 ,  6 ′. The fastening means or devices  7 ,  7 ′ shown here have an outer geometry of the kind that such they can simultaneously serve as the holder means or device already mentioned above in order to fasten the plug connector module  5  in a holding frame  2 . The fastening means or devices  7 ,  7 ′ shown here have a dual function as it were and are therefore provided with the reference signs  7  and  8  in  FIG. 3  at the same time. 
       FIGS. 5 and 6  show a second exemplary embodiment of the plug connector module  5 ′ according to the invention. The plug connector module  5 ′ shown here also comprise or consist of a first functional unit  6  and a second functional unit  6 ′ which are each independent in respect of their technical manner of operation. A fastening means or device  7 ,  7 ′ is respectively integrally formed on a side surface of the functional units  6 ,  6 ′. The fastening means or device  7  of the first functional unit  6  is designed substantially as a recess. The fastening means or device  7 ′ of the second functional unit  6 ′ has a dovetail shape which matches the recess. This so-called dovetail connection has been found to be a particularly stable manner of fixing the functional units  6 ,  6 ′ since it can withstand high transverse forces. The dovetail connection is also reversible, and therefore the functional units  6 ,  6 ′ can be reused and/or combined in a different way. A holder means or device  8  is respectively integrally formed on the opposite side surface of the functional units  6 ,  6 ′. 
       FIG. 5  illustrates a sectional illustration of the plug connector module  5 ′ in a plane in the plugging direction SR. It can be seen in said Figure that the width B S  or the width of the broad side of the plug connector module  5 ′ is composed of the width B F  of two functional units  6  (B S =B F +B F ⇔BF=2BF).  FIG. 6  illustrates a sectional illustration of the plug connector module  5 ′ in a plane transverse to the plugging direction SR. The depth B T  or the width of the narrow side of the plug connector module  5 ′ is marked here. The width B T  of the plug connector module  5 ′ corresponds to the width of the functional unit  6 . Owing to the above-described transverse division of the plug connector module  5  into two functional units  6 ,  6 ′, a virtually square cross section of the individual functional units  6 ,  6 ′ is achieved. Virtually square means that the depth B T  of the functional units  6 ,  6 ′ corresponds approximately to the width B F  of the functional units  6 ,  6 ′. The difference in length between the depth B T  of the functional units  6 ,  6 ′ and the width B F  of the functional units  6 ,  6 ′ is less than or equal to 10 percent (≤10%). 
     Contact elements with a large cross section or diameter can also be used owing to transverse division of the plug connector modules  5 ,  5 ′ . . . of this kind.  FIG. 6  shows two functional units  6 ,  6 ′ which have openings  13  with a large diameter, for receiving contact elements with a correspondingly large cross section or diameter. Contact elements of this kind could no longer be used in the case of longitudinal division of the plug connector module  5 ′. 
     The holding frame  2  consists of two frame halves are 9 which are connected to one another in an articulated manner. Openings  10  are respectively provided in the respective frame halves  9  of the holding frame  2 , the holder means or devices  8  of the plug connector module  5 ,  5 ′ or of the plug connector modules  5 ,  5 ′ entering said openings during insertion. When the frame halves are 9 are folded together, the holder means or devices  8  enter the openings  10  completely, as a result of which interlocking holding of the plug connector module  5 ,  5 ′ or of the plug connector modules  5 ,  5 ′ is produced in the holding frame  2 . The holder means or devices  8  have different dimensions. The associated openings  10  are adapted in a corresponding manner, so that so-called polarization is created by way of the holder means or devices  8 . The plug connector modules  5 ,  5 ′,  5 ″, . . . can be inserted into the holding frame  2  only with a specific orientation. 
       FIG. 7  illustrates a third variant embodiment of the plug connector module  5 ″ according to the invention. The plug connector module  5 ″ consists of two functional units  6 ,  6 ′ and is equipped with the same fastening means or devices  7 ,  7 ′ or holder means or devices  8 ,  8 ′ as the first embodiment. Here too, the fastening means or devices  7 ,  7 ′ for reversibly fixing the functional units perform the function of holder means or devices  8 ,  8 ′ for fixing the plug connector module  5 ″ in a holding frame  2  at the same time. The plug connector module  5 ″ has a strain-relief element  11  which is arranged between the functional units  6 ,  6 ′. The strain-relief element  11  has two openings  12  on the cable connection side. A cable tie (not shown) for fixing and strain relief of a cable (not shown) which is connected to the plug connector module  5 ″ can be passed through the openings  12 . The strain-relief element  11  is equipped with a further opening (not shown for reasons of illustration) between the functional units  6 ,  6 ′, so that the fastening means or devices  7 ,  7 ′—for fixing the functional units  6 ,  6 ′—can interengage. Owing to the strain-relief element  11 , the plug connector module  5 ″ is somewhat wider, and therefore it is more tightly clamped by the frame halves  9  of the holding frame  2  in the installed state. As a result, a shear movement of the functional units  6 ,  6 ′ of the plug connector module  5 ″ is effectively prevented. The strain-relief element  11  can be manufactured from a metal material and therefore also provide electromagnetic shielding of the two functional units  6 ,  6 ′ from one another. 
       FIG. 8  shows a further exemplary embodiment of a plug connector module  5 ′″ according to the invention.  FIG. 8  shows two functional units  6 ,  6 ′ which have, as fastening means or devices  7 ″, a partially circular contour and a corresponding receptacle for it. The functional units  6 ,  6 ′ can be reversibly connected to one another by way of a rotational movement. The rotational movement ends as soon as a stop contour  15  of a functional unit  6 ,  6 ′ opens into the recess  14  of the other functional unit  6 ,  6 ′, which recess is provided for said stop contour, and latches there. 
       FIGS. 9 and 10  show a further exemplary embodiment of a plug connector module  5   IV  according to the invention. Said figures show two further functional units  6 ,  6 ′ which can be reversibly latched to one another by way of latching contours  16  and corresponding recesses  17  by way of a tilting movement. 
       FIG. 11  shows a further exemplary embodiment of a plug connector module  5   V  according to the invention. One functional unit  6  is illustrated in a transparent manner for reasons of illustration. The functional units  6 ,  6 ′ each have studs  18  and sockets  19  on the facing sides and can be reversibly latched to one another in accordance with the Lego principle. 
       FIG. 12  shows a further exemplary embodiment of a plug connector module  5   VI  according to the invention. The functional units  6 ,  6 ′ can be reversibly connected to one another by way of a frame-like latching plate  20 . The latching plate  20  has a latching arms  30  which point in the plugging direction and have end-side latching hooks  21  which engage into recesses of the functional units  6 ,  6 ′, which recesses are provided for them. The holder means or devices  8  are integrally formed on the latching plate  20 . Accordingly, the above-described polarization of the plug connector modules  5   VI  is realized by way of the latching plate  20  when said plug connector modules are inserted into the holding frame  2 . Therefore, the individual functional units  6 ,  6 ′ do not need to contain any polarization means and can be permutated with one another as desired. The latching plate  20  may consist of an elastic, metal material and can therefore also perform a shielding or grounding function in parallel. 
       FIGS. 13 and 14  show a further exemplary embodiment of a plug connector module  5   VII  according to the invention. The two functional units  6 ,  6 ′ can be reversibly latched to one another by way of a complex structure  22 . 
       FIG. 15  shows a further exemplary embodiment of a plug connector module  5   VIII  according to the invention. The two functional units  6 ,  6 ′ are reversibly connected to one another by way of a separate connecting means or device  23 , shown in  FIG. 16 . The functional units  6 ,  6 ′ have T-shaped grooves on their connecting surface, it being possible for the double-T-carrier-like connecting means or device  23  to be pushed into said slots. 
       FIG. 17  shows a further exemplary embodiment of a plug connector module  5   IX  according to the invention. The first functional unit  6  has, in each of the end regions, outwardly pointing webs  26  with respectively internal recesses  24 . The second functional unit  6 ′ has a box contour  27  which fits between the webs  26 . Pins  25 , which match the recesses  24  of the webs  26 , are integrally formed on the end regions of the box contour  27 . The pins  25  engage into the recesses  24  when the functional units  6 ,  6 ′ are brought together, as a result of which reversible fixing of the functional units  6 ,  6 ′ to one another is realized. 
       FIG. 18  shows a further exemplary embodiment of a plug connector module  5   X  according to the invention. Said Figure shows the cross section of a plug connector module  5   X  from above. The plug connector module  5   X  shown here consists of a framework  28  on which holder means or devices  8  for installation into a holding frame  2  are already integrally formed. The framework  28  has two receiving regions  29  for in each case one functional unit  6 ,  6 ′. There are no holder means or devices  8  integrally formed on the functional units  6 ,  6 ′ themselves. As a result, the functional units  6 ,  6 ′ can be inserted into the receiving regions  29  in a flexible manner. 
     Even though various aspects or features of the invention are shown respectively in combination in the figures, it is clear to the person skilled in the art—unless stated otherwise—that the illustrated and discussed combinations are not the only ones possible. In particular, mutually corresponding units or feature complexes from different exemplary embodiments can be exchanged with one another. 
     In general, in the following claims, the terms used should not be construed to limit the claims to the specific embodiments disclosed in the specification and the claims, but should be construed to include all possible embodiments along with the full scope of equivalents to which such claims are entitled.