Patent Description:
Electrical connections generally comprise mating electrical connectors. One connector may be a male connector and may include pins or a plug configured to mate with another (female) connector having sockets, openings or recesses for receiving the pins. Inside such female coupling features, a corresponding pin may be arranged for the electrical contact.

The two parts of an electrical connection are manufactured separately and may be manufactured with different materials, and manufacturing technologies. The male and female electrical connectors may be manufactured by different entities and may be manufactured with different manufacturing tolerances. These manufacturing tolerances may affect the mating of the connectors both in an axial direction, and in a transverse plane perpendicular to the axial direction. The axial direction may herein be regarded as the direction of mating of the plug and socket coupling.

Electrical connections may be made between a power source (e.g. an electrical grid, a battery or other) and a component. Electrical connectors may sometimes be mounted with some flexibility, e.g. they may be attached to wiring or a flexible cable. In this case, connecting an electrical connector may be relatively easily done. Even a misalignment between the two electrical connectors, which may be caused by manufacturing tolerances can be compensated by one of the connectors or both of the connectors displacing. <CIT> discloses a coaxial connector includes front and rear bodies and front and rear contacts that can float relative to one another during mating with another coaxial connector. A wave washer between the front and rear bodies ensures contact between the front and rear bodies and urges the front and rear bodies toward axial parallel alignment with one another. <CIT> discloses an electrical connector assembled component including a first attachment connector for attaching to a first circuit board member; a second attachment connector for attaching to a second circuit member; and an intermediate connector that is provided between the first attachment connector and the second attachment connector.

The present disclosure however relates to electrical connectors which may be rigidly mounted in place and which may be connected to rigid or semi-rigid transmission lines, e.g. an electrical coupling to a battery, a relatively thick electrical cable or rigid busbars.

In one example, such busbars may be connected e.g. to a battery of a vehicle such as a car. With such a rigid system, a misalignment between male and female subassemblies cannot readily be compensated. And it may thus be found that mating the electrical connector of a component (male or female) with an electrical connector (female or male) of the electrical circuit can be complicated.

The present disclosure in various examples provides electrical connectors of an electrical connection and electrical connections which allow suitable mating of the electrical connectors even in case of inaccuracies or high tolerances in manufacturing of the separate connectors, and even in case of rigid mountings or connections of the connectors.

In a first aspect, an electrical connector as defined in claim <NUM> is provided. Preferred embodiments are the subject of the dependent claims.

In accordance with this first aspect, an electrical connector is provided that can adapt for misalignment, and for some mismatch in dimensions between the electrical connector and the mating connector. The potential mismatch due to e.g. manufacturing tolerances may be compensated in a transverse direction (i.e. perpendicular to the direction of mating of the electrical connectors) by biasing members pushing the contacts away from the terminals. A user may attempt to mate the female coupling parts with the male coupling parts and since the contacts are movable in the transverse direction, they will displace as needed.

Along the transverse axis, or in a transverse plane, the electrical contact with the terminals can be ensured with suitable shaping and sizing of the inner ends of the contacts and the second ends of the terminals. Unlike some prior art systems, no components beyond the electrical connector need to be modified. standard busbars may be used.

Throughout the present disclosure, the term "transmission line" is to be understood as a cable or busbar or any other structure designed to conduct electricity. The terminals as used throughout the present disclosure may particularly relate to fixed terminals, i.e. terminals that cannot displace, or only have very limited movement. Such fixed terminals may be relatively rigidly mounted or fixedly mounted to other components.

According to the present invention, each of the first and second terminals comprises a contact brush for electrically connecting with the inner end of the floating contacts. The contact brushes provide frictional contact allowing relative displacement between terminals and contacts (or contact carriers).

According to the present invention, at least one of the first and second terminals may comprise one or more biasing members configured to urge the contact brush in contact with the inner end of the floating contacts. Optionally, the biasing members may comprise springs. Other elastic or resilient biasing members may also be used. The biasing members may ensure or improve contact between the contact brushes and the contacts. Moreover, in some cases they can allow for a potential mismatch (e.g. due to manufacturing tolerances) in the axial direction to be absorbed.

In some examples, a dimension of the inner ends of the first and second contacts along the transverse axis may be different from a dimension of the first and second terminals along the transverse axis. Along the transverse axis, or in the transverse plane the inner ends of the first and second contacts may have an increased diameter, or length and/or width with respect to the first and second terminals. Alternatively, the first and second terminals may be enlarged (e.g. have increased radius, diameter, length and/or width) with respect to the first and second contacts. In both cases, a relative displacement is allowable while maintaining electrical contact. In yet further examples, the contacts and terminals may be similarly sized, while allowing a transverse displacement without loosing an electrical connection.

In some examples, the electrical connector may comprise a single contact carrier comprising the first and the second contact. With a single contact carrier, a distance between the two contacts may be fixed. In some other examples, the electrical connector may comprise a first contact carrier comprising the first contact and a second contact carrier comprising the second contact, and wherein the second contact carrier is movable along the transverse axis with respect to the first contact carrier. With separate contact carriers, a distance between the first and second contacts (e.g. pins) may be adapted, such that a potential mismatch in a distance between the contacts can be adapted for as well by moving one contact carrier with respect to the other.

In some examples, a flexible joint may be arranged between the first and the second contact carrier. Such a flexible joint may be flexible both in an axial direction and/or in a transverse direction.

In some examples, the electrical connector may comprise a gasket arranged between a sidewall of the housing and the contact carriers. The gasket may be resilient or flexible at least in the transverse plane. The gasket may allow for displacement in the transverse plane, while at the same time ensures appropriate sealing and can avoid e.g. dust, dirt or water to reach the terminals, or the electrical circuit behind the electrical connector in general.

In some examples, the contacts of the contact carriers may form plugs or pins for mating with sockets of the mating connector. Alternatively, the contact carriers may comprise sockets (in which the contacts may be arranged) for mating with plugs of the mating connector.

<FIG> schematically illustrate an example of an electrical connector <NUM>. The electrical connector <NUM> may be arranged in a vehicle, e.g. a car and may provide an electrical connection between a power source e.g. a car battery and an electrical system in the car. The car may be a hybrid or an electric vehicle. The electrical systems may be or include particularly an electric engine, but in other examples may include auxiliary systems such illumination, cameras and many others.

In a specific example, the electrical connector may be provided for high power DC transmission. High power may herein be regarded as having a current higher than 100A e.g. more than 200A or 300A.

The electrical connector <NUM> is arranged for electrically connecting a mating connector (not shown) to a first transmission line i.e. first busbar <NUM> and a second transmission line i.e. second busbar <NUM>. The first busbar <NUM> may be connected to a positive electrode of a car battery, and the second busbar <NUM> may be connected to a negative electrode of a car battery.

The electrical connector <NUM> includes a housing <NUM> carrying a first terminal <NUM> having a first end 21A for contacting the first busbar <NUM>, and a second terminal <NUM> having a first end 22A for contacting the second busbar <NUM>. The electrical connector <NUM> further comprises one or more contact carriers <NUM> comprising a first contact <NUM> and a second contact <NUM>.

The first and second contacts <NUM>, <NUM> have an inner end 42A, 44A electrically connected to the second ends 21B, 22B of the first and second terminals <NUM>, <NUM> respectively, and having an outer end 42B, 44B for electrically connecting with corresponding contacts of the mating connector (not shown).

One or both of the first and second contacts may be "floating" contacts, i.e. they may be movably arranged within the housing <NUM>. In this particular case, the single contact carrier <NUM> is movably arranged and the contact carrier <NUM> carries both the first and second contacts <NUM>, <NUM>. Both the first and second contacts <NUM>, <NUM> are therefore movably arranged, but they move in unison.

The electrical connection between the first and second contacts <NUM>, <NUM> with their respective terminals <NUM>, <NUM> comprises a first and second contact brushes <NUM> that are in contact with the inner end of their respective contact <NUM>, <NUM>. A contact brush <NUM> may be made from e.g. carbon or copper.

Biasing members <NUM> configured to urge the contact brushes <NUM> to their respective contacts <NUM>, <NUM> may be provided for assuring the electrical connection between them. The biasing members can increase and/or ensure the frictional contact between contact brushes <NUM> and contacts <NUM>, <NUM>. Furthermore, the biasing members <NUM> urging the contact brush towards the contacts may also absorb some linear misalignments in an axial direction. The contact carrier <NUM> is substantially movable along a transverse axis with respect to the housing <NUM>. A dimension of the inner ends 42A of the first and second contacts <NUM>, <NUM> along the transverse axis may be larger than a dimension of the first and second contact brushes <NUM> along the transverse axis. In this particular case, the diameter of the inner ends 42A, 44A of the first and second contacts <NUM>, <NUM> is larger than a diameter of the contact brushes <NUM>.

In the particular example of <FIG>, the electrical connector <NUM> comprises a single contact carrier <NUM> comprising and carrying both the first <NUM> and the second contact <NUM>. It will be illustrated however in other example, that the contact carrier may be split in parts. Or, in other words, that the electrical connector may comprise more than one contact carrier <NUM>.

In the particular example of <FIG>, the housing <NUM> comprises a first housing (or "terminal housing") <NUM> and a second (or "contact housing") <NUM>. The first housing forms the physical structure in which or to which the terminals and transmission lines are attached. The second housing forms the physical structure in which the mating of the electrical connectors take place.

In other examples, a single integrally formed housing may be used. The housing(s) may be made from suitable insulating material, such as e.g. a plastic. Injection moulding may be used in some examples for the manufacture of the housing. In this particular example, the housing comprises a retaining member to limit an axial separation between the contact carriers and the first and second terminals. The retaining member in this example is a housing flange <NUM> configured to engage with a flange <NUM> of the contact carrier <NUM>.

In this particular example, a gasket <NUM> is arranged between a sidewall of the housing <NUM> and the contact carrier <NUM>. In this particular case, the gasket <NUM> is arranged between the contact carrier <NUM> and the first housing <NUM>. In other examples, the gasket may instead be arranged in contact with the second housing <NUM>.

The gasket <NUM> may be substantially cylindrical in the case of a cylindrical connector <NUM> and it may be resilient or have elasticity i.e. it may have some flexibility to deform and the ability to return to its original shape after a deformation. The resiliency or elasticity may come from the shape of the gasket and/or from the material of the gasket. A suitable material for the gasket may be an elastomer, such as e.g. a rubber, silicone or a thermoplastic elastomer.

The gasket <NUM> may provide sealing between the cavity where the connection between the contacts and its respective terminal is made and the environment. In this way, dirt, dust and water from the environment in which the electrical connector is placed is prevented from reaching said connection.

A further seal <NUM> may be provided in this example between first housing <NUM> and second housing <NUM>. Any suitable seal may be used.

In this example, the biasing members may include springs <NUM>. The springs <NUM> may be helicoidal springs. In other examples, other biasing members that provide a biasing force through e.g. elasticity or resiliency of a material of the biasing member on the contact carrier pushing it away from the busbars <NUM> and <NUM> may be used.

The first and second terminals <NUM>, <NUM> in this example include a cylindrical holder <NUM> housing the spring <NUM> that pushes the brush <NUM> into contact with the first and second contacts <NUM>, <NUM>. An electrical contact in this example is established between first and second terminals <NUM>, <NUM> through the brush <NUM> and the first and second contacts <NUM>, <NUM>. The contact may be established through sidewalls of the holder <NUM> to the brush <NUM> and / or through the biasing member <NUM> to the brush <NUM>.

In alternative examples, the second ends 21B, 22B of the terminals and inner ends 42A, 44A of the contacts <NUM>, <NUM> may be differently shaped and sized, while allowing a relative displacement without loosing the electrical connection. For example, fixed bus contacts may be larger than the inner ends of the contacts. It should be clear that the cross-sectional shape of the contacts and terminals may vary, and may be e.g. circular, annular, rectangular, square or different.

The functioning of the electrical connector <NUM> may be illustrated with reference to <FIG> and <FIG>. Busbars <NUM> and <NUM> may be relatively rigid. The busbars <NUM> and <NUM> may be fixed to the terminals <NUM>, <NUM>. Suitable fasteners, such as screws or bolts may be used to fix the busbars <NUM>, <NUM>, terminals <NUM>, <NUM> and housing <NUM> rigidly in place.

A mating connector (not shown in <FIG>) may not exactly mate with the connector <NUM>. This may be due e.g. to manufacturing tolerances. In <FIG>, it may be seen how a variation in the transverse plane may be compensated. A neutral line <NUM> may indicate a theoretical centric position of the contact carrier <NUM> with respect to the housing <NUM>. In the top figure, the contact carrier is displaced to the left with respect to the neutral line <NUM>. In the bottom figure, the contact carrier <NUM> is displaced to the right with respect to the neutral line <NUM>. In some examples, a variation of +/- <NUM> along a transverse axis may be compensated. In some examples, a variation of +/- <NUM> in the transverse plane may be compensated i.e. in any direction of the transverse plane.

It may also be seen in <FIG> how the dimensions of inner ends 42A, 44A of contacts <NUM>, <NUM> in the transverse plane allow the brush <NUM> to maintain contact in spite of a displacement. In practice, a user may try to mate the connector <NUM> with another connector and thereby force contact carrier to a position in the transverse plane in which mating is possible. The resiliency of gasket <NUM> means that the contact carrier is movable in the transverse plane. The gasket may continue to provide sealing between contact carrier and an inside of a side wall of housing <NUM> in the various positions. The biasing members <NUM> additionally may push the brushes away from the terminals and force them to touch and connect with the contacts. When a user attempts to engage the connector with a mating connector, he/she will thereby push the contacts <NUM>, <NUM> and/or contact carrier inwards against the force of the biasing members. The biasing members at all intermediate positions ensures contact between brush <NUM> and a inner end 42A, 44A of the contacts <NUM>, <NUM>.

The manufacturing tolerances may also cause a mismatch in the axial direction (z). the mating connector may, when mounted, reach closer or further away from the busbars <NUM>, <NUM>.

It may be seen in <FIG> how the electrical contact <NUM>, <NUM> may be maintained for the different axial positions. In the figure on the left hand side, the biasing members <NUM> are more extended, i.e. a distance between the inner end 42A, 44A of the contacts <NUM>, <NUM> is larger than in the situation on the right hand side of <FIG> (in which the biasing members <NUM> are more compressed). A neutral line <NUM> may indicate a theoretical position of the contact carrier in the absence of manufacturing tolerances. In some examples, a variation of +/- <NUM> with respect to the neutral line may be compensated.

<FIG> schematically illustrate a further examples of an electrical connector <NUM> engaging with a mating connector <NUM>. <FIG> shows a cross-sectional and exploded view of the various part of the electrical connection. <FIG> show connector <NUM> and mating connector <NUM> in different relative positions during mating. <FIG> shows an isometric exploded view.

Similarly as in the example of <FIG>, the electrical connector <NUM> of <FIG> may electrically connect a component (electrically connected to mating connector <NUM>) to rigid busbars <NUM> and <NUM>. Terminals <NUM>, <NUM> are attached to busbars <NUM> and <NUM> with a suitable fastener <NUM>. The fastener <NUM> may clamp the terminals <NUM>, <NUM> in fixed contact with busbars <NUM>, <NUM> respectively. The terminals are thereby substantially fixed in place. The holder of the contact brush <NUM> may be a threaded bush, for mating with a suitably threaded fastener <NUM>.

A spring <NUM> may be arranged inside a cylindrical holder in terminals <NUM>, <NUM>. The spring <NUM> may push against an inner side of a brush <NUM> which in turn can push against a inner end 42A, 44A of electrical contacts <NUM>, <NUM>. The electrical contact may be made from a suitable conducting material such as e.g. copper, or copper alloys or brass alloys. An insulating sleeve <NUM> may be arranged around contacts <NUM>, <NUM>. Contact <NUM>, <NUM> with sleeve <NUM> may form a "plug" or male coupling element which can mate with a suitable female coupling element on mating connector <NUM>. It should be clear however, that in other examples, the male and female features may be interchanged between the connector <NUM> and mating connector <NUM>.

In this particular example, the electrical connector <NUM> may carry further mechanical protrusions or guiding pins <NUM> to ensure proper mating and fitting with connector <NUM>. The guiding pins <NUM> may engage with a guiding socket on the mating connector and can increase stability during the connection process as the contact carrier <NUM> is relocated within the housing <NUM>.

A difference between the example of <FIG> and the example of <FIG> is that the contact carrier <NUM> is integrally formed with the second housing or "contact housing". A sealing or gasket <NUM> comprises a central cylindrical portion and an annular portion surrounding the central cylindrical portion. The annular portion may be compressed radially and thereby provides the movable or floating arrangement of the contact carrier <NUM> in the transverse plane, as was already illustrated with reference to <FIG>.

In this particular example, the gasket <NUM> may include flanges that engage with a rear surface of the housing <NUM>. The gasket may thus be fitted about the housing <NUM> and snap in place and stay in place. In this particular example, the gasket <NUM> may include a retention feature to limit the axial separation of the contact carrier <NUM> and the first and second busbars <NUM>, <NUM>.

Similarly as in <FIG>, the cross-sectional dimensions of the contacts <NUM>, <NUM> at a inner end may be larger than the cross-sectional dimensions of the brush <NUM>. This allows for a relative transverse displacement between the contacts <NUM>, <NUM> and the housing <NUM> while maintaining contact.

<FIG> schematically illustrates yet a further example of an electrical connector <NUM> rigidly mounted to busbars <NUM>, <NUM>. The electrical connector <NUM> of <FIG> is generally similar to the example of <FIG> and allows compensation in the transverse plane through elasticity or flexibility of the seal <NUM>. Also, some compensation in the axial direction (z-axis) through biasing members <NUM> may be provided as before. However, the electrical connector of this example comprises a first contact carrier 40A comprising the first contact <NUM> and a second contact carrier <NUM> B comprising the second contact <NUM>, and wherein the second contact carrier 40B may be movable along the transverse axis with respect to the first contact carrier <NUM> A.

The electrical connector may further comprise a flexible joint <NUM> between the first and the second contact carriers 40A, 40B. The flexible joint <NUM> may allow relative movement along the transverse axis x, or generally in the transverse plane. Alternatively or additionally, the flexible joint <NUM> may allow axial relative movement, i.e. along the z-direction. Separate contact carriers 40A, 40B allow a displacement of the contacts <NUM> and <NUM> with respect to each other, such that a misalignment in this sense on the mating connector can also be compensated. A flexible joint can have the effect that one of the first and second contacts drags the other contact in the same direction as mating of electrical connectors take place.

In any of the examples, the contact carriers <NUM> may comprise plugs carrying the contacts (or the contacts may be the plugs) for mating with sockets of the mating connector. Alternatively, the contact carriers <NUM> may comprise sockets carrying the contacts for mating with plugs of the mating connector.

<FIG> schematically illustrate yet a further example of an electrical connector <NUM> rigidly mounted to busbars <NUM>, <NUM>. The electrical connector <NUM> may form part of a vehicle power supply in this example. The electrical connector <NUM> is configured to mate with electrical connector and may thereby provide power to a mechatronic system of the vehicle.

The electrical connector <NUM> of <FIG> is generally similar to the example of <FIG> and allows compensation in the transverse plane through elasticity or flexibility of the seal or gasket <NUM> arranged between contact carrier <NUM> and housing <NUM>. Also, some compensation in the axial direction (z-axis) through biasing members <NUM> may be provided as before. Housing <NUM> may be made from a suitable insulating material such as a plastic.

The electrical connector <NUM> of this example comprises a contact carrier <NUM> comprising first and second contacts <NUM>, <NUM>. In this particular case however, the first and second contacts <NUM>, <NUM> are arranged in sockets <NUM> of the contact carrier. The sockets <NUM> may be formed as insulating sleeves, and the metallic contacts <NUM>, <NUM> inside the sockets <NUM> make contact with pins <NUM> and <NUM> of the mating connector <NUM>. The metallic contacts may be seen to extend through contact carrier <NUM> in order to make contact with first terminal <NUM> and a second terminal <NUM> (see also <FIG>). As before, a contact brush <NUM> is urged towards contacts <NUM>, <NUM> by a spring <NUM> and electrical contact is established and can be maintained even with some transverse movement, and some axial movement.

The electrical connector <NUM> may comprise a plastic housing <NUM>, and may provide electrical power towards a mechatronic system through buses <NUM>, <NUM>. Buses <NUM>, <NUM> may be connected to connector <NUM> through suitable fasteners <NUM>.

A difference between the electrical connector <NUM> of <FIG> and e.g. the connector of <FIG> is further that no guiding pins and sockets or other guiding features for mating of the connectors are provided.

The example of <FIG> is comparable to the example of <FIG>. The electrical connector <NUM> of this example may mate with a connector <NUM> that is the same or very similar to the connector <NUM> of <FIG>. The electrical connector <NUM> and mating connector <NUM> may also be used for similar purposed. As in <FIG>, the electrical connector <NUM> has sockets <NUM> in single contact carrier <NUM>. But the single contact carrier has first and second electrical contacts which are movably arranged within the contact carrier, and are thus also movable with respect to the housing.

The contact carrier <NUM> may be moved with respect to the housing to a gasket <NUM> which offers some flexibility or deformability. The contact carrier <NUM> comprises a flexible mounting element <NUM> which enables movements of the contacts in the transverse plane, also with respect to each other. The flexible mounting element <NUM> may derive its flexibility from its material (it may be made e.g. from a rubber, silicone, or elastomer), from its shape(due to e.g. folds) or both.

The flexible mounting element <NUM> may comprise a deformable part 49A and 49B surrounding the first and second contacts <NUM>, <NUM> respectively. The flexible mounting element may also comprise a more rigid part 49C in an area between the first and second contacts. The rigid part may be more centrically arranged than the deformable parts 49A and 49B. An edge or rim portion 49A surrounding the contacts. Deformable and rigid herein are not to be understood as absolute terms, as the flexible mounting element may be made entirely from a relatively flexible material. Rather, it is meant that an are of the central portion 49B may be more readily deformable than another area. The deformable parts 49A and 49B may comprise e.g. folds, crests and troughs to allow for movement.

In between the first and second contacts <NUM>, <NUM>, a central rib <NUM> of the contact carrier may be arranged. The flexible mounting element <NUM> may allow movement of the first and second contact <NUM>, <NUM> with respect to the stiffer central rib <NUM> and surrounding walls of the contact carrier <NUM>.

In some alternative examples, the gasket <NUM> may be relatively rigid. in such an example, the contact carrier as a whole has less or no movement possibility. The flexible mounting element <NUM> may still allow for one or both contacts to displace as needed for mating.

Even though in the illustrated examples, a direct current (DC) coupling was shown, in other examples, an alternating current (AC) coupling may be used. Even though in the illustrated examples, only a first and second contact carried by the contact carrier(s) are shown, it should be clear that the contact carrier may carry additional contacts (e.g. an earthing pin). In yet further examples, an electrical connector might include more electrical connections to more than two transmission lines.

In further non-illustrated examples, the electrical connector <NUM> may include further or different features for mating with another connector. Such features may be structural features i.e. non-electrical connections.

Claim 1:
An electrical connector (<NUM>) for electrically connecting a mating connector (<NUM>) to a first (<NUM>) and a second (<NUM>) transmission line comprising:
a housing carrying a first terminal (<NUM>) having a first end (21A) for contacting the first transmission line (<NUM>), and a second terminal (<NUM>) having a first end (22A) for contacting the second transmission line (<NUM>),
one or more contact carriers (<NUM>; 40A, 40B) comprising a first contact (<NUM>) and a second contact (<NUM>), and
the first and second contacts (<NUM>, <NUM>) having an inner end (42A, 44A) electrically connected to a second end (22A; 22B) of the first and second terminals (<NUM>, <NUM>) respectively, and having an outer end (42B, 44B) for electrically connecting with corresponding contacts of the mating connector,
wherein an axial direction is defined as a direction of mating of the electrical connector (<NUM>) with the mating connector (<NUM>), and a transverse axis is defined as an axis that is perpendicular to the axial direction,
wherein one or both of the first and second contacts (<NUM>, <NUM>) are floating contacts, wherein the floating contacts are substantially movable along the transverse axis with respect to the housing (<NUM>), and
wherein the inner end (42A; 44A) of the floating contacts (<NUM>, <NUM>) and the second end (21B, 22B) of the corresponding terminal (<NUM>, <NUM>) are configured such that a movement of the floating contacts is allowed while maintaining an electrical connection between the floating contacts (<NUM>, <NUM>) and the corresponding terminal (<NUM>, <NUM>),
characterized in that each of the first and second terminals (<NUM>, <NUM>) comprises a contact brush (<NUM>) for electrically connecting with the inner end (42A, 44A) of the floating contacts, and each of the first and second terminals (<NUM>, <NUM>) comprises one or more biasing members (<NUM>) configured to urge the contact brush (<NUM>) in contact with the inner end (42A; 44A) of the floating contacts.