Patent Description:
There are electrical connection assemblies comprising a shielded connector and counter-connector (see for example <CIT>, <CIT> and <CIT>). Each one of these connector and counter-connector comprises a housing in which at least one electrical contact and at least one shielding element are housed. In the case of electrical connection assemblies configured to transmit high currents (for example in electric, hybrid or plug-in hybrid vehicles) the shielding elements are configured to reduce the influence on the environment of potential electromagnetic disturbances generated by these high currents. To this end, electrical continuity is sought between the shielding of the connector and the shielding of the counter-connector. As described in <CIT> contact tabs are then provided on at least one of the shielding elements of the connector, these contact tabs being configured to establish a connection with a shielding element of the counter connector. Each of these contact tabs is in the form of a deformable lamella and comprises a junction portion and a contact portion. The contact tab is connected to the body of the shielding element only via the junction portion and is shaped so that the contact portion projects from a surface of the body.

This type of contact tabs can cause the shielding of one connector to be incorrectly connected to the shielding of the other connector. For example, it may happen that the contact tabs are deformed during storage between the manufacture of the shielding element comprising these contact tabs and the assembly of this shielding element in a connector. Furthermore, these contact tabs are often very flexible and do not necessarily provide sufficient contact force.

A shielded connection assembly, a connector and a method of manufacturing a shielding element for this connection assembly are described below, which contribute at least partially to overcome at least one of the aforementioned drawbacks.

Thus, according to claim <NUM>, an electrical connection assembly for a motor vehicle electrical circuit is described, comprising a connector and a counter-connector. The connector comprises at least one first shielding element and the counter-connector comprises at least one second shielding element. The first shielding element comprises a body formed from a metal sheet from which at least one resilient contact tab is cut out. This contact tab or tongue extends along a longitudinal direction. It comprises at least one junction portion and a contact portion projecting from a surface of the body. This contact tab is connected to the body only by the junction portion. It is configured to make electrical contact with the second shielding element, when the connector is mated with the counter connector.

In this connection assembly, each contact tab comprises an interference portion which is connected to the remainder of the body only via a longitudinal segment, which is itself connected to the body only via the junction portion. In addition, each contact tab is configured so that its interference portion abuts the body of the first shielding element when the connector is mated with the counter connector.

In other words, each contact tab is integral with the body of the first shielding element. It is therefore rigidly connected to the body via the junction portion located at one of its longitudinal ends. But the other longitudinal end is free. However, an interference portion is provided on the contact tab and this interference portion can come to bear on the body so that the movement of the free end is limited. Thus, pressure on the contact portion pushes the interference portion against the body. This limits the deformation of the contact tabs and allows a greater contact force to be maintained than in prior art connection assemblies in which one end of the contact tab is free. Thus this allows for better electrical contact, between the contact tab of the first shielding element and the second shielding element.

This connection assembly also optionally comprises one and/or other of the following features, each considered independently of the other or in combination with one or more others:.

Also described below is a connector comprising a housing, a terminal and at least a first shielding element housed in the housing. The first shielding element comprises a body formed of a sheet metal from which at least one resilient contact tab is cut out which extends along a longitudinal direction. The contact tab comprises at least one junction portion and one contact portion. The contact tab is connected to the body only via the junction portion and is curved, bent, in such a way that the contact portion protrudes from a surface of the body.

Each contact tab further comprises an interference portion configured to be able to interfere with the body of the first shielding element.

Optionally, in this connector, the body of the first shielding element comprises an opening arranged under the contact tab, this opening being bordered by two support zones spaced apart, perpendicularly to the longitudinal direction, by a maximum distance which is less than the largest dimension, perpendicularly to the longitudinal direction, of the interference portion.

Also described below is a method of manufacturing a shielding element for a connection assembly according to claim <NUM>. This method comprises.

Further features and advantages will become apparent in the detailed discussion of various embodiments of the invention, the discussion being accompanied by examples and references to the accompanying drawings.

An example of an embodiment of a connection assembly <NUM> is shown in <FIG>. This connection assembly <NUM> is used, for example, in an electrical power circuit of a motor vehicle. Such a circuit is used, for example, to interconnect components such as a battery, a charging station, a converter, an electric motor, etc..

This connection assembly <NUM> comprises a connector <NUM> and a counter-connector <NUM>. For example, both the connector <NUM> and the counter connector <NUM> comprise a housing <NUM> or <NUM> with two cavities in each of which a power terminal <NUM>, <NUM> is housed. The connector <NUM> and the counter connector <NUM> are two-way power connectors. In the example shown in <FIG>, each connecting channel (way) is individually shielded. For example, two female terminals <NUM> are accommodated in the connector <NUM> and two male terminals <NUM> are accommodated in the counter connector <NUM>. Each power terminal <NUM>, <NUM> is attached and electrically connected to a cable <NUM> comprising a shielding braid. Within the connector <NUM> and the counter connector <NUM> each of the shielding braids is electrically connected to a separate shielding element <NUM>, <NUM>. For example, the connector <NUM> has two first shielding elements <NUM> and the counter connector <NUM> has two second shielding elements <NUM>. The first <NUM> and second <NUM> shielding elements have a generally cylindrical shape with a circular base. They extend longitudinally parallel to a central longitudinal axis A (see <FIG> and <FIG>).

As shown more particularly in <FIG>, each first shielding element <NUM> comprises a body <NUM> formed from a sheet of metal from which resilient contact tabs <NUM> are cut out. Each first shielding element <NUM> thus comprises a plurality of contact tabs <NUM>. For example, there are eight of these contact tabs <NUM>. These contact tabs <NUM> are distributed in pairs symmetrically with respect to the central axis A (see <FIG>). Thus, the contact force exerted by each of the contact tabs <NUM> of a first shielding element <NUM> on a second shielding element <NUM> is better distributed and balanced as well as more uniform.

Each of these contact tabs <NUM> extends along a longitudinal direction parallel to the central axis A. In the embodiment example described herein, each contact tab <NUM> has a "T" shape and comprises a longitudinal segment <NUM> and a transverse segment <NUM>. For example, the longitudinal segment <NUM> extends between a junction portion <NUM> and the transverse segment <NUM>. For example, the longitudinal segment <NUM> comprises a contact portion <NUM> and the transverse segment <NUM> comprises an interference portion <NUM>. Each contact tab <NUM> is oriented from the junction area <NUM> to the interference portion <NUM> in a direction corresponding to the direction of mating of the connector <NUM> with the counter connector <NUM>.

Each contact tab <NUM> is connected to the body <NUM> only by the junction portion <NUM>. In other words, each contact tab <NUM> is cut out from the body <NUM> along a cutting line which runs all the way around the contact tab <NUM> (including the transverse segment <NUM>) except at the junction area <NUM> where the cutting line is interrupted. Each contact tab <NUM> is thus released from the body <NUM>, except at the junction area <NUM>.

The longitudinal segment <NUM> of each contact tab <NUM> is bent so as to lift the contact portion <NUM> from the outer surface <NUM> of the body <NUM>. The contact portion <NUM> thus protrudes from the outer surface <NUM> of the body <NUM>. The longitudinal segment <NUM> has two substantially parallel longitudinal edges, between which the distance defines the width d of the longitudinal segment <NUM>.

The transverse segment <NUM> extends perpendicular to the longitudinal segment <NUM> at a free end of the contact tab <NUM> longitudinally opposite the junction portion <NUM>.

The transverse segment <NUM> has a length L greater than the width l of the longitudinal segment <NUM>. The transverse segment <NUM> has two interference tabs <NUM>. Each interference tab <NUM> is configured to rest on the body <NUM> on either side of an opening <NUM> in the body <NUM>, which is located substantially below the contact tab <NUM>, when the contact portion <NUM> makes an electrical contact with the second shielding element <NUM>. In other words, this opening <NUM> is bordered by two support zones <NUM>, each of the interference tabs <NUM> being brought into superposition of a respective support zones <NUM>.

Furthermore, the first shielding element <NUM> supports a retention ring <NUM>. The retention ring <NUM> comprises a substantially cylindrical wall <NUM> extending longitudinally parallel to the central axis A, between a first <NUM> and a second <NUM> circular edge. Protrusions <NUM> are provided in the vicinity of the first edge <NUM>. These protrusions <NUM> are configured to retain the retention ring <NUM> on the first shielding member <NUM> and to orient the retention ring <NUM> and the first shielding member <NUM> relative to each other. The second edge <NUM> comprises a flange <NUM> the diameter of which is larger than the cylinder forming the wall <NUM>. The cylindrical wall <NUM> has windows <NUM>, each configured and positioned for the passage of the contact portion <NUM> of a respective contact tab <NUM>.

According to an embodiment example, a method for manufacturing a first shielding element <NUM> as described below comprises one or more cutting operations and several forming operations. For example, it comprises an operation of cutting, from a metal sheet, a shape corresponding essentially to the flat shape of the first shielding element <NUM>. This cutting operation thus includes cutting out the body <NUM> of the first shielding element <NUM>. The contact tabs <NUM> are then cut out from the body <NUM>. The body <NUM> also has longitudinal edges <NUM> cut out in a mortise and tenon shape. After this operation, each contact tab <NUM> extends flat along a longitudinal direction.

A first forming operation, by bending the longitudinal segment <NUM>, is therefore carried out to raise the contact portion <NUM> of each longitudinal segment <NUM> with respect to the body <NUM> and to bring the interference portion <NUM> into alignment and superposition with the support zones <NUM>. This first forming operation results in openings <NUM>, each of which is arranged under a contact portion <NUM> and bordered by two support zones <NUM>. This also results in open areas <NUM>, each corresponding to an opening resulting from the cut out of the transverse segment <NUM> of each contact portion <NUM>. The first forming operation is followed by a second forming operation consisting of bending the body <NUM> about the central longitudinal axis A and bringing the longitudinal edges <NUM> into engagement with each other.

As shown in <FIG>, after cutting and shaping operations, the interference portion <NUM> (of each contact tab <NUM>) is in register with a support zone <NUM>, on the outer surface <NUM> of the first shielding element <NUM>. Thus, as shown in <FIG>, when the connector <NUM> is coupled to the counter-connector <NUM>, the first shielding element <NUM> is at least partially inserted into the second shielding element <NUM>. The contact portion <NUM> engages under the second shielding element <NUM>. The bending of the unstressed contact tab <NUM> is such that the height of the contact tab <NUM> below the contact portion <NUM> is greater than the space E between the first <NUM> and second <NUM> shielding elements. When the connector <NUM> and the counter connector <NUM> are mated, the contact portion <NUM> is therefore pushed towards the outer surface <NUM> of the body <NUM> of the first shielding element <NUM> and the contact tab <NUM> is flattened. This causes the interference portion <NUM> to interact with the support zone <NUM> via the interference tabs <NUM>. However, this interaction of the interference portion <NUM> with the support zone <NUM> limits the deformation of the contact tab <NUM>, which then exerts a greater contact force, by the contact portion <NUM>, on the second shielding element <NUM>.

Furthermore, the first <NUM> and second <NUM> shielding elements are configured in such a way that, when the connector <NUM> and the counter-connector <NUM> are mated, the openings <NUM> and open areas <NUM> of one are covered by a solid area of the other. In this way, the shielding performance is optimised.

Claim 1:
Electrical connection assembly (<NUM>) for a motor vehicle electrical circuit, comprising a connector (<NUM>) and a counter-connector (<NUM>), the connector (<NUM>) comprising at least one first shielding element (<NUM>) and the counter-connector (<NUM>) comprising at least one second shielding element (<NUM>), the first shielding element (<NUM>) comprising a body (<NUM>) formed from a sheet metal from which at least one resilient contact tab (<NUM>) is cut out, extends along a longitudinal direction and comprises at least one junction portion (<NUM>) and one contact portion (<NUM>) protruding from a surface of the body (<NUM>) and configured to establish an electrical contact with the second shielding element (<NUM>), when the connector (<NUM>) is coupled to the counter connector (<NUM>),
wherein each contact tab (<NUM>) comprises an interference portion (<NUM>) which is connected to the remainder of the body (<NUM>) only via a longitudinal segment (<NUM>) which is itself connected to the body (<NUM>) only via the junction portion (<NUM>), and wherein each contact tab (<NUM>) is configured so that the interference portion (<NUM>) abuts the body (<NUM>) of the first shielding element (<NUM>) when the connector (<NUM>) is mated with the counter connector (<NUM>),
wherein the body (<NUM>) of the first shielding element (<NUM>) has openings (<NUM>) arranged under each contact tab (<NUM>), said openings (<NUM>) each corresponding to an opening resulting from the cut out of the longitudinal segment (<NUM>) of each contact tab (<NUM>), and each of said openings (<NUM>) being bordered by two support zones (<NUM>) spaced perpendicularly to the longitudinal direction, by a maximum distance which is less than the largest dimension, perpendicularly to the longitudinal direction, of the interference portion (<NUM>).