Power connector, and electrical connection element and assembly method therefor

Patent metadata

Field	Value
Publication number	US-9819117-B2
Application number	US-201615250026-A
Country	US
Kind code	B2
Filing date	Aug 29, 2016
Priority date	Jul 16, 2015
Publication date	Nov 14, 2017
Grant date	Nov 14, 2017

Abstract

An electrical connection element is for a power connector. The power connector has an electrical component including a first insulative housing and a first mating assembly having a number of first electrical mating members structured to be substantially enclosed by the first insulative housing. The electrical connection element includes a second insulative housing; and a second mating assembly comprising a number of second electrical mating members structured to be electrically connected to the number of first electrical mating members. The second mating assembly is structured to move between a first position corresponding to the number of second electrical mating members being substantially enclosed by the second insulative housing, and a second position corresponding to the number of second electrical mating members being partially disposed external the second insulative housing.

First claim

What is claimed is:

1. An electrical connection element for a power connector, said power connector comprising an electrical component including a first insulative inner housing, a first insulative outer housing, and a first mating assembly having a number of first electrical mating members structured to be substantially enclosed by said first insulative inner housing and said fist insulative outer housing, said electrical connection element comprising:
a second insulative housing having an extension portion structured to extend into said electrical component between said first insulative inner housing and said first insulative outer housing: and
a second mating assembly comprising a number of second electrical mating members structured to be electrically connected to said number of first electrical mating members,
wherein said second mating assembly is structured to move between a first position corresponding to said number of second electrical mating members being substantially enclosed by said second insulative housing, and a second position corresponding to said number of second electrical mating members being partially disposed external said second insulative housing;
wherein said number of second electrical mating members is a number of male conductors; wherein each of said number of male conductors has a first end portion and a second end portion disposed opposite and distal the first end portion; wherein said second insulative housing comprises an insulative panel and a number of insulative receiving portion each extending from said insulative panel toward a respective first end portion; wherein each of said number of male conductors at least partially extends through a corresponding one of said number of insulative receiving portions; wherein said extension portion is annular-shaped; and wherein said insulative panel is disposed generally internal the extension portion.

2. The electrical connection element of claim 1 wherein each respective insulative receiving portion has a distal portion disposed at said insulative panel; wherein, when said second mating assembly is disposed in the first position, each respective second end portion is disposed between a corresponding first end portion and a corresponding distal portion; and wherein, when said second mating assembly moves from the first position toward the second position, each respective male conductor slides at least partially through said corresponding distal portion in order to be at least partially disposed external said second insulative housing.

3. The electrical connection element of claim 1 wherein said panel is generally planar; and wherein said panel connects each of the receiving portions to one another.

4. A power connector comprising:
an electrical component comprising:
a first insulative inner housing,
a first insulative outer housing, and
a first mating assembly comprising a number of first electrical mating members structured to be substantially enclosed by said first insulative inner housing and said first insulative outer housing, and

an electrical connection element comprising:
a second insulative housing having an extension portion structured to extend into said electrical component between said first insulative inner housing and said first insulative outer housing, and
a second mating assembly comprising a number of second electrical mating members structured to be electrically connected to said number of first electrical mating members,

wherein said second mating assembly is structured to move between a first position corresponding to said number of second electrical mating members being substantially enclosed by said second insulative housing, and a second position corresponding to said number of second electrical mating members being partially disposed external said second insulative housing;
wherein said number of first electrical mating members is a number of female conductors; wherein said number of second electrical mating members is a number of male conductors; wherein, when said second mating assembly is disposed in the second position, each of said number of male conductors extends into a corresponding one of said number of female conductors in order to electrically connect said electrical connection element to said electrical component; wherein each of said number of male conductors has a first end portion and a second end portion disposed opposite and distal the first end portion; wherein said second insulative housing comprises an insulative panel and a number of insulative receiving portions each extending from said insulative panel toward a respective first end portion; wherein each of said number of male conductors at least partially extends through a corresponding one of said number insulative receiving portions; wherein said extension portion is annular-shaped; wherein said insulative panel is disposed generally internal the extension portion; and wherein, when said second mating assembly is in the second position, the extension portion extends into said electrical component between said first insulative inner housing and said first insulative outer housing.

5. The power connector of claim 4 wherein said number of female conductors is a plurality of sleeves; and wherein said number of male conductors is a plurality of pins.

6. The power connector of claim 4 wherein said electrical component is a line side electrical receptacle; and wherein said electrical connection element is a load side electrical receptacle.

7. The power connector of claim 4 wherein each respective insulative receiving portion has a distal portion disposed at said insulative panel; wherein, when said second mating assembly is disposed in the first position, each respective second end portion is disposed between a corresponding first end portion and a corresponding distal portion; and wherein, when said second mating assembly moves from the first position toward the second position, each respective male conductor slides at least partially through said corresponding distal portion in order to be at least partially disposed external said second insulative housing.

8. A method of assembling a power connector comprising the steps of:
providing an electrical connection element comprising a first insulative housing and a number of first electrical mating members substantially enclosed by said first insulative housing, said first insulative housing having an extension portion;
providing an electrical component comprising a second insulative inner housing, a second insulative outer housing, and a number of second electrical mating members structured to be substantially enclosed by said second insulative inner housing and said second insulative outer housing, said extension portion being structured to extend into said electrical component between said second insulative inner housing and said second insulative outer housing;
aligning said number of first electrical mating members with said number of second electrical mating members;
pushing said electrical connection element and said electrical component toward one another, thereby causing said number of first electrical mating members to move independently with respect to said first insulative housing and be partially disposed external said first insulative housing; and
mechanically engaging said number of second electrical mating members with said number of first electrical mating members;
wherein said extension portion is annular-shaped; and wherein the pushing step further comprises:
inserting the extension portion into said electrical component between said second insulative inner housing and said second insulative outer housing.

9. The method of claim 8 wherein said number of first electrical mating members

Assignees

• Eaton Corp

Inventors

• Rollmann Paul Jason
• Juds Mark Allan
• Eckroth Kurt Von

Classifications

• H01R43/16

  for manufacturing contact members, e.g. by punching and by bending · CPC title

• H01R13/42

  Securing in a demountable manner · CPC title

• H01R13/635

  by mechanical pressure, e.g. spring force · CPC title

• H01R13/53 Primary

  Bases or cases for heavy duty; Bases or cases {for high voltage} with means for preventing corona or arcing · CPC title

• H01R13/62977

  Pivoting levers actuating linearly camming means · CPC title