FR3053845A1 - METHODS OF MANUFACTURING AND CONNECTING A CONNECTOR - Google Patents

Abstract

The invention relates to a method for manufacturing a female connector (18) in which a power female contact (1) and an insulating housing (17) are provided. The power female contact (1) is made of a first electrically conductive metallic material and comprises at least one elastic tongue (13). The insulating housing (17) has a front end coupling (25). Also provided is a sleeve (7) made of a second material, possibly metallic and electrically conductive, surrounding each elastic tongue (13) and extending, beyond each elastic tongue (13), to a front end ( 26) at most at a standardized distance from the front end of coupling (25). The invention also relates to a method of connecting this female connector (18) with a male connector.

Description

Holder (s): DELPHI INTERNATIONAL OPERATIONS LUXEMBOURG S.A R.L. Limited liability company.

Extension request (s)

Agent (s): DELPHI FRANCE SAS Simplified joint-stock company.

(□ 4) METHODS OF MANUFACTURING AND CONNECTING A CONNECTOR.

FR 3 053 845 - A1 (5 /) The invention relates to a method of manufacturing a female connector (18), in which a female power contact (1) and an insulating housing (17) are provided. The female power contact (1) is made of a first electrically conductive metallic material and comprises at least one elastic tab (13). The insulating housing (17) has a front coupling end (25). There is also provided a sleeve (7) made of a second material, possibly metallic and electrically conductive, surrounding each elastic tongue (13) and extending, beyond each elastic tongue (13), to a front end ( 26) located at a maximum at a standardized distance from the front coupling end (25).

The invention also relates to a method of connecting this female connector (18) with a male connector.

Methods of manufacturing and connecting a connector [ooi] The invention relates to the field of automotive connectors. More particularly, the invention relates to a method of manufacturing a female power connector for a motor vehicle, as well as a method of connecting such a connector with a male power connector.

Power connectors can be used in particular in hybrid and electric vehicles to connect electric charging cables and / or different components of a power circuit (converters, batteries, motors, etc.). Such connectors must be able to withstand currents of up to 63A, 97A, or even 125 A. In order to withstand high current densities, the male and female electrical power contacts used in these connectors must be relatively large. In addition, they are generally machined in one piece from a bar of material, in order to distribute the streamlines within them as evenly as possible.

In addition, in order to minimize overheating at the contact points, at least certain areas of the contacts, and in particular those at which the electrical contact points are established between the male and female power contacts, are coated with 'a noble metal such as silver. It is thus possible to limit or avoid oxidations and / or reduce the resistance to this contact.

Large power contacts, possibly coated with noble metals are relatively expensive to manufacture. So we are looking for more economical solutions.

However, constraints are imposed for the production of these connectors. For example, certain dimensions of the boxes of insulating material in which the power contacts are housed can be defined by standards. Thus, the standard VC075 revCD 62196-2 IEC 201009-27 requires that the end of a female power contact housed in the cavity of a box is located 7.2mm from the end of this box, considered in relation to to the longitudinal direction of the female contact. In this case, if the dimensions of the male contact intended to be inserted there remain the same, it is essentially the dimensions of the insulation of the housing of the female connector which dictate the length of the female power contact.

There is then provided according to the invention a method of manufacturing a female connector, in which a female power contact is provided and an insulating housing. The female power contact is made of a first electrically conductive metallic material. This female power contact extends in a longitudinal direction. It has a base and a socket. This socket itself comprises at least one elastic tongue formed integrally with the base, this elastic tongue extending longitudinally from the base towards a free end. The insulating housing has a front coupling end and a cavity opening, towards the front coupling end, on an opening for the introduction of a power male contact. The female power contact is then placed in the cavity, with the socket towards the rear of the cavity and the socket towards the front of the cavity, that is to say, oriented towards the opening. And we also provide a sleeve made of a second material, possibly metallic and electrically conductive (but it can be made of plastic), surrounding the sleeve and extending from the sleeve in the direction of the opening, beyond each elastic tongue, up to a front end situated at the maximum at a standardized distance (that is to say imposed by a norm, standard or specification) from the front coupling end.

Thus, thanks to these provisions, the sleeve makes it possible to extend the base and the socket in the longitudinal direction, with possibly less material and / or a less expensive material than if the female power contact in its entirety had been manufactured. like the base and the socket. However, the standardized distance (7.2 mm in the case of standard VC075 revCD 62196-2 IEC 201009-27) between the front end of the female power contact and the front end of coupling of the insulating housing is respected thanks to the presence of the sleeve which partially replaces the socket which otherwise would have been longer.

This method of manufacturing a female connector optionally includes one and / or the other of the following characteristics considered independently of one another or in combination with one or more others:

- the sleeve is at least partially coated with a noble metal and the sleeve has no coating;

- The second material is a copper alloy, such as brass.

[Ooii] According to another aspect, the invention relates to a method of connecting a female power connector produced as indicated above, with a male power connector comprising at least one male power contact, in which the male connector is coupled. the female power connector by inserting the male power contact into the opening of the female connector housing, until the interference distance between the tab and the male power contact is at least 1mm .

Optionally, the interference distance between the tab and the male power contact is less than 50% of the length of the portion of the male power contact engaged in the female power contact (including sleeve).

Optionally, when connecting the female power connector with the male power connector, an electrical contact is made between a first control contact present in the female power connector and a second control contact present in the male connector power, after having made an electrical contact between the female power contact and the male power contact.

According to yet another aspect, the invention relates to a female connector comprising a female power contact and an insulating housing. The female power contact is made of a first electrically conductive metallic material. It extends in a longitudinal direction and has a base. It also includes a socket itself comprising at least one elastic tongue integrally formed with the base. This elastic tongue extends longitudinally from the base to a free end. The insulating housing has a front coupling end and a cavity opening, towards the front coupling end, on an opening for the introduction of a power male contact. The female power contact is housed in the cavity, with the socket facing the opening. A sleeve made of a second material, possibly metallic and electrically conductive, surrounds the sleeve and extends from the sleeve in the direction of the opening, beyond each elastic tongue, to a front end situated at the maximum. at a standard distance from the front coupling end.

Optionally, the total length of the sleeve and the base is less than 70% of the total length of the base and the sleeve.

Optionally, the socket is made of a copper alloy at least partially coated with silver and the sleeve is made of brass.

According to yet another aspect, the invention relates to a connection assembly comprising a female power connector as mentioned above and a male power connector, in which the interference distance between the tongue and the male power contact is less than 50% of the length of the portion of the male power contact engaged in the female power contact.

Other features and advantages of the invention will appear on reading the detailed description which follows, as well as in the accompanying drawings. In these drawings:

- Figure 1 shows schematically in perspective a female electrical power contact, intended to be housed in a female power connector according to the invention;

- Figure 2 shows schematically in side elevation, the body of the female electrical power contact of Figure 1;

- Figure 3 shows schematically in side elevation, the female electrical power contact of Figure 1 in which is inserted a male electrical power contact;

- Figure 4 shows schematically in perspective and in section a portion of a female power connector according to the invention in which is housed the female electrical power contact of Figure 1;

- Figure 5 shows schematically in section of the respective portions of male and female connectors coupled;

- Figures 6A and 6B schematically represent the coupling sequence of the male and female connectors of Figure 5.

In this document the terms "front", "rear", etc. are purely conventional and refer, where appropriate, to the orientations as shown in the figures.

FIG. 1 shows an exemplary embodiment of a female power electrical contact 1. This extends longitudinally in a direction D between a rear end 2 and a front end 3. The end rear 2 is intended to be connected to a cable (not shown) by welding or crimping, for example. The front end 3 is open so that a male contact 4 of male connector 5 can be inserted there (see also Figures 3 and 5).

This female power electrical contact 1 comprises a body 6, towards the rear end 2, and a sleeve 7, towards the front end 3. The body 6 and the sleeve 7 are two separate parts, each consisting of a different material. The body 6 consists of a first electrically conductive material such as a copper alloy (for example CuNiPblP). The body 6 is machined and bored in a bar of the first electrically conductive material. The body 6 itself comprises a base 8 and a socket 9 (see FIG. 2). The base 8 has a fixing end 10 intended to be connected to a cable. It also has a groove 11, between two ribs 12, intended to receive an O-ring (not shown). The sleeve 9 comprises at least one elastic tongue 13. In the example shown in FIGS. 1 to 4, the sleeve 9 comprises six tongues 13 symmetrically distributed around a central longitudinal axis A parallel to the direction D. Each elastic tongue 13 extends longitudinally from the base 8 towards a free end 24. The sleeve 9 has an internal surface directed towards the axis A, coated with a layer of noble metal, such as silver, at least at the level of the contact zones 14 of the tabs 13 (that is to say zones intended to establish electrical contact with a male contact 4 of power). For example, the noble metal layer covers the entire body (internal and external surfaces) over 40pm thick.

The machining of the body 6 is carried out by removing material (It is then understood that this operation produces a relatively large amount of waste when the body is machined in a bar whose length here corresponds to that of the body provided with its sleeve ). The sleeve 7 consists of a cylinder extruded from a second electrically conductive metallic material. For example, the second electrically conductive metallic material is brass (for example CuZn39Pb3). Unlike the machining of the body 6, the production of the sleeve 7 does not produce (or little) waste.

The sleeve 7 extends between the base 8 and a front end 26. It covers the sleeve 9, and therefore the tongues 13 over their entire length. The sleeve 7 is force fitted onto the sleeve 9. The sleeve 9 protects the tongues 13. A shoulder 15 is machined between the base 8 and the sleeve 9 so that the external surface of the sleeve 7 is in continuity with that of the pellet 8.

The body 6 measures for example 27.25mm, while the entire length of the female power contact 1 (that is to say when the sleeve 7 is fitted on the body 6) is 42.25mm . So the length of the body 6 (ie the entire length of the base 8 and the socket 9) is approximately 60% of the length of the female power contact 1 (therefore of the total length of the base 8 and of the sleeve 7). The female power contacts of the prior art used for this type of application measure 42.25mm. The use of female power contacts 1 according to the invention saves 36% of the first raw material compared to what is required to manufacture female power contacts of the prior art. In addition, the saving of noble metal (Ag) is 41%.

The tongues 13 are slightly inclined (for example by 3 ° relative to the longitudinal direction D), from the rear towards the front, towards the inside of the sleeve 9 relative to the direction D of so as to be pushed elastically radially outwards from the socket 6, in the direction of the sleeve 7, when a male contact 4 of a male connector 5 is inserted between the tongues 13.

As shown in Figure 4, the female power contact 1 (body 6 and sleeve 7) is housed in a cavity 16 formed in an insulating housing 17 (molded plastic) of a female connector 18. The one of the ribs 12 abuts on a shoulder 19 located in the cavity 16. The front end 3 of the female power contact 1 is located near an opening 20 formed in the insulating housing 17 and intended for the introduction of 'a male contact 4 of male connector 5. This opening 20 is slightly set back from a front edge 21 of the insulating housing 17. This front edge 21 forms the part located most forward of the insulating housing 17, in other words an end before mating 25.

More specifically, as shown in Figures 4 and 5, the front end 3 of the female power contact 1, corresponding to the front end 26 of the sleeve 7, is at a standardized distance d = 7.2mm from the edge front 21, corresponding to the front coupling end 25 of the housing 18, this distance being measured in a direction parallel to the longitudinal direction D.

As shown in Figure 5, when a male connector 5 and a female power connector 18 are coupled, a male contact 4 of a male power connector is introduced through the opening 20 and is inserted between the tabs 13, with which an electrical contact is established. The interference distance I between the tongues 13 and the male contact 4 is for example 3mm. It is noted that this interference distance I is relatively short, because the tongues 13 are short and the contact zones 14 are located in the rear half of the sleeve 7. In other words, the interference between the male contacts 4 and female power 1 is made only on a small portion of the male contact power 4, located towards its free end. For example, this portion corresponds to less than 50%, even less than 25%, of the length of the male contact engaged in the female contact of power 1. Thus, the friction distance (which corresponds to the interference distance I) between the male contact 4 and the tabs 13 is smaller. There is therefore less wear on the coating of the male contact

4.

The electrical contact between the male and female power contacts is only established when the coupling between the male 5 and female 18 connectors is almost complete.

Indeed, in order to avoid in particular the formation of electric arcs, the male 5 and female 18 connectors are provided with control or signal contacts 22, 23. These control contacts 22, 23 are intended to open or close a power current control circuit passing through the male 4 and female 1 power contacts. As shown in FIGS. 6A and 6B, the control contacts 22, 23 are arranged relative to each other respectively in the male and female connectors so as to establish electrical contact between them only after the tabs 13 of the power female contact 1 have established electrical contact with a male contact 4 of the male connector 5. In FIG. 6A, the tongues 13 are in physical contact but the male and female connectors are not yet coupled, the electrical contact between the contacts 22, 23 is not yet established, the power control circuit is still open and no current flows between the tabs 13 and the male contact 4. In FIG. 6B, the male and female connectors are in position complete coupling, the electrical contact between the control contacts 22, 23 is established, the power control circuit is closed, the tongues 13 are in ph contact ysique and electric, a power current can pass between the tabs 13 and the male contact 4. The length of the contacts 4, 23 of the male connector is not reduced, unlike that of the contacts 22, 13 of the female connector.

Claims (11)

Claims 1. Method for manufacturing a female connector (18), in which a female power contact (1) and an insulating housing (17) are provided, the female power contact (1) being made of a first metallic material electrically conductive, extending in a longitudinal direction (D) and comprising a base (8) and a socket (9) itself comprising at least one elastic tongue (13) made integrally with the base (8), this elastic tongue ( 13) extending longitudinally from the base (8) towards a free end (24), and o the insulating housing (17) comprising a front coupling end (25) and a cavity (16) opening out, towards the front end of coupling (25), on an opening (20) for the introduction of a male power contact (4), the female power contact (1) is placed in the cavity (16), with the socket (9) oriented towards the opening (20), characterized in that one provides t also a sleeve (7) made of a second material, surrounding the sleeve (9) and extending from the sleeve (9) in the direction of the opening (20), beyond each elastic tongue (13 ), up to a front end (26) located at the most at a standardized distance from the front coupling end (25). 2. A method of manufacturing a female connector (18) according to claim 1, wherein the socket (9) is at least partially coated with a noble metal and the sleeve (7) has no coating. 3. Method of manufacturing a female connector (18) according to one of the preceding claims, in which the second material is a copper alloy. 4. Method for connecting a female power connector (18) manufactured using the method according to one of the preceding claims, with a male power connector (5) comprising at least one male power contact (4) , in which the male power connector (5) and the female power connector (18) are coupled by inserting a male power contact (4) in an opening (20) in the housing (17) of the female power connector (18 ), until the interference distance (I) between the tab (13) and the power male contact (4) is at least 1mm. 5. Connection method according to claim 4, in which the interference distance (I) between the tongue (13) and the power male contact (4) is less than 50% of the length of the male contact portion of power (4) engaged in the power female contact (1). 6. Connection method according to claim 4 or 5, wherein during connection of the female power connector (18) with the male power connector (4), an electrical contact is made between a first control contact (22) present in the female power connector (18) and a second control contact (23) present in the male power connector (18), after having made an electrical contact between the female power contact (1) and the male contact Power 4). 7. Female connector comprising a female power contact (1) and an insulating housing (17), o the female power contact (1) being made of a first electrically conductive metallic material, extending in a longitudinal direction (D) and comprising a base (8) and a socket (9) itself comprising at least one elastic tongue (13) integrally formed with the base (8), this elastic tongue (13) extending longitudinally from the base (8) towards a free end (24), and o the insulating housing (17) comprising a front coupling end (25) and a cavity (16) opening, towards the front coupling end (25), on an opening ( 20) for the introduction of a male power contact (4), the female power contact (1) being placed in the cavity (16), with the socket (9) oriented towards the opening (20), characterized by the fact that a sleeve (7) made of a second material, ent oure the sleeve (9) and extends from the sleeve (9) towards the opening (20), beyond each ίο elastic tongue (13), up to a front end (25) located maximum at a standardized distance from the front coupling end (25). 8. The connector of claim 7, wherein the total length of the sleeve (9) and 5 of the base (8) is less than 70% of the total length of the base (8) and the sleeve (7). 9. The connector of claim 7 or 8, wherein the socket (9) is made of a copper alloy at least partially coated with silver and the sleeve (7) is made of brass. 10. Connection assembly comprising a female power connector (18) according to one of claims 6 to 9, and a male power connector (5), and in which the interference distance (I) between the tongue (13 ) and the male power contact (4) is less than 50% of the length of the portion of the male power contact (4) engaged in the 15 female power contact (1). 2/2