DE102007038219B3 - Plug pin for use in e.g. plug bridge, has connection end for connection to connection wire, and middle area leading from connection end to contact end, where connection end is designed as crimped end and middle area is designed to be hollow - Google Patents

Abstract

The plug pin (1) has a connection end (2) for connection to a power line connection wire, and a middle area (4) leading from the connection end to a contact end (3) on a socket contact. The connection end is designed as a crimped end (2a) and the middle area is designed to be hollow, where the plug pin is made of an electrically conducting material e.g. stainless steel. A funnel-shaped extension is formed at the connection end, where the plug pin is manufactured through a shaping process. An independent claim is also included for a method for manufacturing a plug pin.

Description

The The present invention relates to the term claimed above and thus deals with connector pins, their manufacture and Use.

Pins are known per se. They are used in plugs of electrical equipment to allow contact between the electrically conductive wire of the power cord to the live contacts in a power outlet. A known pin is shown for example in the DE 196 27 335 C1 , To produce the pins made of solid material cutting processes are used, which also leads to increased material costs in recycling the chip material.

pins become typical in connector bridges fixed in which they are geometrically correct distance from each other and with the correct supernatant be poured into electrically insulating plastic material. The plug bridge can Erdfederbügel, as well as in certain applications filter elements and the like exhibit. When making a power cord using this connector bridge will be then first strip the strands of a power cord and then secure connected to the connecting ends of the plug pins. After striking the strands is formed around the connection area around the handle body, typically with PVC by injection molding. The handle body isolated the contacts against contact and may provide strain relief, etc.

The Variety of electrical appliances, the daily Life needed be, shows that the power cord and thus also plug jumper as well The parts used like plug pins are bulk goods. As such The corresponding parts are manufactured under considerable cost pressure. Despite the cost pressure it is necessary to have a high degree of security to ensure, because production errors can quickly be deadly consequences for the user of the power plug, through fires or because the user has an electrical shock due to processing errors receives.

There are already a variety of connector pins known. So is out of the DE 102 03 171 A1 an electrical connector pin with electrically conductive core known in extrusion technology, wherein the electrical connector pin is to be inserted into a power outlet and an electrically conductive core with a contact area for electrically contacting the power outlet and a connection area for contacting an electrical component should have. It will be in the DE 102 03 171 A1 indicated that the electrically conductive core is produced in an extrusion molding process. The electrically conductive core should in particular serve for a European plug and be encased in a central region with an electrically insulating sheath.

A deformation of a metal alloy by extrusion for the production of electrical brush contacts is from the U.S. Patent 4,597,281 known. In this case, brush contacts are to be manufactured with different diameter at opposite ends in a multi-stage process.

An electrical connector consisting essentially of two identically directed plug contact parts or of a plug contact part and a rectified to the latter connector, wherein in the region of the transition of the two parts in communication with each other outwardly projecting, at least approximately over the entire circumference of the connector extending, in sharp edges ending, flange-like position stop is provided, is from the DE 31 23 850 C2 known. It is stated that the position stop should be formed by an annular outer region of a circular end element integrally formed on one end of one of the two parts or of a circular separating element located between the two parts. Although a non-cutting production is specified, but not explicitly addressed to extrusion molding.

Extrusion forming is also mentioned in the DE 100 41 516 A1 However, which relates to a high-voltage electrical connection device with a receptacle for an electrical conductor to which the connection device is to be permanently attached, and a resilient plug contact for connection to a mating connector. The resilient ends shown make the arrangement for power plugs unsuitable. In addition, a multi-part arrangement is shown.

It is desirable to specify a power plug, which offers a high level of security at low overall costs.

The Object of this invention is new to the commercial application provide.

The solution this task will be more independent Claimed form. Preferred embodiments can be found in the dependent claims.

The present invention thus proposes, in a first aspect, a plug pin with a connection end for connection to a power cord and a molded with extrusion molding, leading from the connection end to a socket contact side contact end Central region, in which it is provided that the connecting end is formed as a crimp end and the central region at least substantially hollow.

One The first essential aspect of the present invention thus consists in the knowledge that the pin are significantly improved can by making a hollow shaping of the middle area at the same time is provided with the creation of a Crimpendes. The middle area gets even if it is formed hollow, by the extrusion molding a change the material properties. This is especially true when the pin made of solid material, which is possible, but not mandatory is required. The entering in the extrusion molding property change of the central area leads amazingly, to an improvement in the mechanical stability of the same, so that even at comparatively thinner Wandungsausbildung the middle area and thus high material savings no kinking or other deformation is expected, such as they can occur, for example, in the case of drumming tests, which plug connectors regularly subject to to get an approval. Also in the course of a production process occurring processing steps do not lead to a deformation that by the extrusion molding formed, usually solidified central areas. nevertheless Contrary to expectations, a crimping at the end of the connection is still possible. This was not, at least not to be expected without further ado, because that Crimping is a highly dynamic process and one through the reshaping solidified and possibly even too brittle or solidified material is typically undesirable here. It but it was found that, despite the improvements in the mid-range a crimping in the connection area still remains possible, possibly is due to that there are other forming conditions there. The education thus enabled the plug pin makes it possible to produce lighter plug pins, which in particular require less starting material. Because the cavity in the middle area to the plug handle body can also be closed by a suitable crimping, and that, when properly executed the Crimping as readily achievable on an industrial scale is, plastic fluid-tight, will not penetrate PVC in to fear the cavity be, nor a concomitant additional material consumption. Nor is it necessary to still use the connection area additional Isolate material. This not only has a cheapening of the Total plug through the material savings result, but saves also transport weight, which is increasing in global transport routes Meaning is, for example, bridge bridges, power cables and electrical appliances in each case be manufactured in other places and afterwards the finished electrical appliances to consumers over a long distance Distances should be spent.

Especially it is preferred if the connection end Netzanschlusslitzenseitig is extended. This facilitates the striking, d. H. Feeding the power cord. In principle would be it is possible that Netzanschlusslitzenzuführung to facilitate through superior plastic funnel, with the superior Plastic funnel can be integral with a connector bridge body, in which the pin is poured, and / or attached to this. However, it is preferably, instead and / or preferably additionally, the connection end itself to expand immediately. This can be done by creating a funnel-shaped contour happen, as well as by providing Crimflügeln, the one V- or U-shaped Crimp result. The actual Form of the connection end can also depend on which Country of the respective pin is determined because at certain Plug pins geometries in the base plate different feeders the power cord can be preferred. Reference is made in this regard Differences between about plugs for Germany and plugs for the UK.

It by the way mentioned, that the pin for both the connection to a neutral or phase conductor can be determined as well as for contacting a ground or ground connection. As a pin in the present case also understood a pin, which not only for the conventional 240 or 120 volts AC power is determined, but also a such pin as he for Plug is used in three-phase networks.

at funnel-shaped preferred extension of the connection end may be an extension given to a measure in which the introduction of Forming from the end of the connection is possible. As a forming agent can Press punches are used, as well as (hydrostatic) active fluids. It should be noted that the present invention is both options allows.

Of the Safety plug is, as already stated, preferred for power plugs and in particular for Double protection or safety plug of European standard be dimensioned.

Since the pin is intended and suitable for use in plug bridges, it is preferred if, close to the connection end in that area which is wrapped in the plug bridge formation of plastic, a shaping is made, the pin against torsion or free rotation in the connector bridge plastic mass and / or protects against undressing. As protection against loosening by torsion knurls, recesses or impressions have proven, ie Formge tions that break a circular symmetry of the plug pin in the region of the plug bridge plastic mass or in the area that is provided for wrapping by plug bridge plastic compound. The shaping can be done during extrusion molding, for example by pressing material against an external extrusion die, and / or subsequently.

Of the Connector pin can be formed of solid material. In this case He is with a suitable press stamp or press fluid with provided the hollow middle area. This can be done by means of a pressed in Stamp done or by pumping fluid. alternative it is also possible assume a hollow element, d. H. a piece of pipe more suitable Length of one Extrusion forming to subjugate. In extrusion molding and / or in a different step, the contact side End be reshaped so that a standard rounding results. Such a can be closed without problems so far that an intrusion of foreign bodies is prevented, so there is no danger that a user through contact one caught at the top and with this in the Socket inserted into a phase conductor, z. B. by moisture or intrinsically conductive object such as a thin copper strand to damage comes.

It It should be noted that it is not absolutely necessary exclusively an extrusion molding but this is preferred because it is so considerable advantages in the production are connected.

The Dimensioning of the hollow area can be chosen so that the weight of the central area considered in isolation, a maximum of 70%, preferably including, most preferably, at most 40% of one in the outer dimensions same full piece is. If the weight saving is less than 30%, the benefits obtained with the connector pin of the present invention, in particular the saving of expensive metal material, lower. If the wall thicknesses are too low, on the other hand, the stability of the plug pin becomes greater impaired. But it is to be estimated that with suitable material also weight reductions of the middle range possible be bigger than that which are specified here as preferred. In principle it is that the weight reduction as big as possible should be, but the required stability tests such as fall drum tests and the like are still to exist. In this respect, the above Specify areas where a problem-free realization can be assumed without the invention to be considered limited thereto is.

Of the Pin is preferably made of brass or stainless steel. It will be appreciated that the materials used may be chosen to provide extrusion molding of the required extent without cracks or other destruction bear. It will also be appreciated that dependent by national or international regulations other than the specified materials are used and that optionally in case of changes National regulations materials currently for legal reasons can not be used yet for the Be usable invention.

protection is also claimed for a plug bridge with at least one connector pin according to the present invention, a power cord with such a jumper as well an electrical device having such a power cord. Furthermore, protection claimed for a method for producing an arrangement according to the invention.

The The invention will be described below by way of example only with reference to the drawings described. In this is represented by

1a an inventive pin in the cast in a plug bridge base plate state in longitudinal section;

1b Cross sections at different heights through the pin.

To 1a includes a general with 1 designated pin 1 a connection end 2 for connection to a power cord, not shown, and molded with an extrusion molding, from the connection end 2 to a socket-side contact end 3 leading mid-range 4 , where the middle area 4 like through cavity 4a shown, is hollow and the connecting end 2 as a crimping end 2a is formed.

The pin 1 is intended in the present example for a double safety plug and is in use in a 5 indicated plug bridge base plate 5 cast in plastic material. It is made of a suitable electrically conductive material, here the preferably usable brass. The usability with other metals, especially stainless steel, is explicitly mentioned and disclosed.

At the end of the connection 2 is at 2 B a funnel-shaped extension is provided, which is the insertion of the power cord as seen from the direction indicated by arrow 6 is intended to facilitate, without protruding strands can affect the safety of the finished power plug. It should be noted that the expansion funnel 2 B to the plug bridge base plate 5 belonging, formed of plastic insertion funnel may be pre-set and / or the eventual use of plastic funnels without extension of the connecting end is possible. However, it is preferable to both funnel the connecting end region to expand and to provide an additional plastic insertion funnel. It should be noted that various arrangements for the formation of superior funnels and their training to the pin out are already known and that such prior art arrangements with the pin of the present invention can be used. Mention should be made in particular superior plastic funnel, which are formed flat to the pin out; those which are cone-shaped in the form of a double cone; and those which are plate-shaped, ie have a first, for example, tapered or cylindrically recessed area to then flatten.

In the cross section of 1b you can see that the clear width in the funnel area 2 B is significantly larger than the clear width in the cavity 4a of the middle area 4 , compare 1b below. Below the insertion funnel 2 B is a crimping area 2a formed so far between the power line strand stop surface 5a of the plug bridge main body 5 and the funnel-shaped opening at 2 B that extends an inserted strand without risk of destruction or damage to the body 5 can be crimped. This is indicated by the double arrow 2d , The appropriate dimensioning of this area will be readily possible for the skilled person. It will be appreciated that the area in which the crimping tools engage in the manufacture of the power plug does not fully extend to the plug bridge base 5a will extend, and that also not, at least compelling, the insertion funnel will be deformed with. A preferred inside width is exemplary in 1b recognizable in the second figure from above. It can also be seen that enough wall material is left by extrusion molding to safely accomplish the crimping without tearing the connector pin or the like. Likewise, the wall thickness is selected so that a dense, in particular gas-tight, but at least PVC-fluid-tight completion of the strand can be obtained.

The contact end 3 is completely closed in the present example, which is done here alone due to the production of the illustrated pin of solid material, ie round wire. When using cut to length pipe sections other ways to close the contact end sufficiently feasible.

The middle area 4 is initially formed hollow and in particular in the area between the contact end 3 and in the use of the power plug to the socket side facing surface of the connector bridge base plate 5 , compare reference number 5b , thin-walled. This is in 1b represented by the cross section at the bottom. It can be seen that a majority of the illustrated cross-sectional area is hollow. It is therefore immediately obvious that this saves considerable weight and material compared to a solid material. The wall thickness is chosen so that on the one hand the proposed current easily finds the required minimum cross-section in the thin wall and on the other hand at the same time both the pin and the potted in a connector bridge pin fall drum tests and the like problem-free. As can be seen, the annular wall is still somewhat thinner in the area of the hollow central area than in the crimp area.

In the area of the connector bridge body 5 is the pin thickened, as at 1b , third cross section from above, and in 1a to recognize. The thickening causes shoulders 4c , which may be slightly sloping, so do not have to protrude perpendicularly from the remaining Steckerstiftwandung, but this can, are formed, which the pin against pulling in the connector bridge body 5 fix. At the same time an outer shape is selected which is not circular, but has a shape deviating from a round shape and, moreover, may be toothed or serrated or has a profile provided along the surface circumference, at least partially, for example in a partial area 4d may be provided, it is not mandatory, the profiling area 4d provided centrally in the connector bridge base plate thickness, and also a plurality of corresponding subregions may be provided. It is only important that a Torsionssicherheitserhöhung can be effected by a fine profiling of the surface still.

The Arrangement is made and processed as follows.

First, a piece of solid material is cut to length and an extrusion mold is provided in which the cut piece is formed into the desired shape by a single extrusion forming step. Then, an extrusion die is introduced into the extrusion matrix loaded with the cut-to-size blank to form the pin. It should be noted that a multi-stage formation process is readily possible with other than extrusion forming steps. A multi-stage forming process by means of extrusion technology is also feasible. In a preferred variant, no thermal aftertreatment is carried out, but the plug pin is further processed without further ado. For this he can in per se conventional manner in a connector bridges be molded body and then the formed connector bridge are provided with a power cord. After striking the power cord then the plug body can be formed by molding with PVC material. There is no risk that PVC material penetrates into the cavity, since the hollow central area is sufficiently secured by the crimping against the ingress of material.

It be mentioned that it is not mandatory, the crimping only in to make a cavity. Instead, a turnaround can also be done of crimpers or the like.

Claims (16)

Pin ( 1 ) with a connection end ( 2 ) for connection to a power cord and a molded extrusion, from the connection end ( 2 ) to a socket contact side contact end ( 3 ) ( 4 ), characterized in that the connecting end as Crimpende ( 2a ) and the central region is hollow. Pin ( 1 ) according to the preceding claim, characterized in that the connecting end ( 2 ) Netzanschlusslitzenseitig is extended. Pin ( 1 ) according to the preceding claim, characterized in that there is a funnel-shaped and / or wing-shaped enlargement. Pin ( 1 ) according to one of the two preceding claims, characterized in that an extension of the connection end ( 2 ) is given to a degree that formers are einpressbar, in particular conical forming agent. Pin ( 1 ) according to one of the preceding claims, characterized in that it is dimensioned for a safety plug, in particular a double safety plug European standard. Pin ( 1 ) according to one of the preceding claims, characterized in that the plug pin for fixing in a plug bridge plastic mass has a torsion and / or Ausziehschutz. Pin ( 1 ) according to the preceding claim, characterized in that the torsion and / or Ausziehschutz is formed by a knurling, recess and / or impression. Pin ( 1 ) according to one of the preceding claims, characterized in that it is formed from a hollow element with extrusion molding. Pin ( 1 ) according to one of the preceding claims with the exception of the immediately preceding claim, characterized in that it is formed of a solid material. Pin ( 1 ) according to one of the preceding claims, characterized in that it is produced at least with a further, different from the extrusion molding process, in particular for Torsionsschutz- and / or Ausziehschutzbildung used forming method. Pin ( 1 ) according to one of the preceding claims, characterized in that the weight of the central region ( 4 ) amounts to a maximum of 70%, preferably a maximum of 40% of a full piece in the outer dimensions. Pin ( 1 ) according to one of the preceding claims, characterized in that the material is formed of brass and / or stainless steel. Connector bridge with at least one connector pin ( 1 ) according to any one of the preceding claims. Power cord with a jumper after one of the preceding claims. Electric device with a power cord according to one of the preceding claims. Method for producing a plug pin ( 1 ) according to any one of claims 1-12, characterized in that for extrusion molding of the plug pin ( 1 ) a method with rigid tools and / or a hydrostatic extrusion process is applied.