DE102017213064B4 - Electrical connector and connector system - Google Patents

Abstract

Electrical connector with a contact body (2) for making electrical contact with a mating contact,
wherein the contact body (2) has:
- A contacting section (3) for electrical contacting of the counter-contact and
-- a connection area (4) for electrical and mechanical contacting of a cable (30),
wherein the connection area (4) extends along a longitudinal axis (A) which defines an axial direction,
two insulation displacement elements (10, 20) each having two cutting edges (11a, 11b, 21a, 21b) lying opposite one another are arranged in the connection area (4),
the two cutting edges (11a, 11b, 21a, 21b) of an insulation displacement element (10, 20) each defining a receiving opening (12, 22) for the cable (30) pointing outwards transversely to the longitudinal axis,
wherein the two receiving openings (12, 22) of the two insulation displacement elements (10, 20) are rotated relative to one another by an angle (α) about the longitudinal axis (A),
the angle (α) being in a range between 40° and 140°.

Description

field of invention

The invention relates to an electrical connector and a connector system

State of the art

Electrical contacts between the line of an insulated cable and a contact body using the so-called insulation displacement contact technique are known from the prior art for electrical connectors and connector systems. The electrical and also mechanical connection of the cable or its line to the contact body of the plug connector is effected or produced by an insulation displacement element instead of by crimping. This insulation displacement element is formed by a pair of opposing blades that form a slot between them. The slit is open to one side. Thus, the pair of cutting edges forms a receiving opening for the cable. The pair of cutting edges can be produced, for example, by one or more slotted brackets with a width that widens towards the receiving opening. The cable is pressed into these slots. In the first part of the slit, the insulation of the cable is usually cut through or, in the case of a layer of paint, this is scraped off. In the end position, the wire comes to rest in a narrow part of the slot and is electrically through-contacted with the lugs or cutting edges due to the high normal forces.

Such a connector is from DE 44 139 77 A1 known.

A connector is known from JP H10-79 267 A, which has two insulation displacement elements in a connection area, which are arranged along a longitudinal axis and each have a receiving opening. The receiving openings point in the same direction perpendicular to the longitudinal axis.

A connector is known from JP H07-57 844 A, which has two insulation displacement elements in a connection area, which are arranged along a longitudinal axis. The two insulation displacement elements are arranged in a V-shape relative to one another, so that the first insulation displacement element is tilted forwards in the direction of the longitudinal axis and the second insulation displacement element is tilted backwards counter to the direction of the longitudinal axis. The two insulation displacement elements are thus twisted relative to one another about a transverse axis transversely to the longitudinal axis.

From the JP 2016 - 110 883 A such a connector is also known. In this case, the two insulation displacement elements are arranged in a zigzag manner rotated relative to one another about a transverse axis to the longitudinal axis.

From the JP S62- 100 953 A a plug connector is known in which two insulation displacement elements are twisted by 180 degrees relative to one another about the longitudinal axis of a connection area.

From the JP S54- 93 796 U a connector is known in which three insulation displacement elements are arranged in a connection area rotated about a longitudinal axis with respect to one another.

Disclosure of Invention

The invention is based on the finding that when the cable moves, e.g. due to bending of the cable or due to vibration stress, micro-movements can occur in the contact point, which leads to wear and thus to a reduced service life of the contact point. Movements in the direction of the slot are particularly critical here, since the forces counteracting the external movement are lower here.

There may therefore be a need to provide a plug connector with insulation displacement technology that is electrically contacted reliably for a long time even when a cable in the plug connector is exposed to increased movement loads.

Advantages of the Invention

This need can be met by the subject matter of the present invention according to the independent claims. Advantageous embodiments of the present invention are described in the dependent claims.

Within the scope of the application, the expressions “comprise” and “have” are used synonymously unless expressly mentioned otherwise.

According to a first aspect of the invention, an electrical plug connector with a contact body for electrically contacting a mating contact is proposed. The contact body has a contact section for making electrical contact with the mating contact and a connection area for making electrical and mechanical contact with a cable. The terminal portion extends along a longitudinal axis that defines an axial direction. Two insulation displacement elements are arranged in the connection area, two of which are opposite each other have cutting edges. The opposing cutting edges form a pair of cutting edges. The two cutting edges of an insulation displacement element each define a receiving opening for the cable that points outwards transversely to the longitudinal axis, the two receiving openings of the two insulation displacement elements being rotated relative to one another by an angle about the longitudinal axis, the angle being at a range is between 40° and 140°.

In other words: the two insulation displacement elements are not aligned parallel to one another with respect to their receiving opening, but are rotated in relation to one another.

This advantageously has the effect in a simple manner that the cable is held better and more reliably, since two clamping/cutting elements are provided instead of just a single one. In addition, the two insulation displacement elements are rotated relative to one another around the longitudinal axis. As a result, relative movements of the cable and contact, e.g. due to thermal loads and/or vibration loads, can be better absorbed, which means that the electrical connection between the connector and the cable is considerably more durable.

The connector can be made of sheet metal, for example.

The connection area can, for example, directly adjoin the contacting section. However, it can also be connected to the contacting section only indirectly, e.g. by means of a neck area arranged between the contacting section and the connection area.

The connection area can, for example, extend as far as a housing of the contact section. In other embodiments, however, it can only extend from one clamping/cutting element to the other clamping/cutting element. The longitudinal axis can also be a longitudinal axis of the entire electrical connector, for example. In this case, the contacting section and the connection area run along the longitudinal axis.

However, it is also possible for the connection area to be tilted relative to the contacting section, e.g. bent by 30° to 150°, e.g. bent by 90°. In this case, the longitudinal axis does not run parallel or even identical to a further longitudinal axis of the contact section. Nevertheless, the functionality of the invention is maintained even in such a kinked case.

The longitudinal axis (of the connection area) can, for example, correspond to an axis along which a cable to be inserted into the two clamping/cutting elements runs in the assembled state.

The fact that the connection area is designed in one piece has the advantageous effect that the connector is designed to be particularly stable in the connection area. This increases the service life. In this way, the connection area can also be produced in a particularly simple and cost-effective manner.

The fact that the electrical connector is designed in one piece has the advantageous effect that the connector is designed to be particularly stable overall. This increases its lifespan. In addition, it can be produced in a particularly simple and cost-effective manner.

Because the electrical connector is manufactured as a stamped and bent part, the connector can be manufactured particularly cost-effectively. For example, the connector can be made from a thin metal sheet.

The fact that the two insulation displacement elements are spaced apart from one another in the axial direction has the advantageous effect that a cable can be inserted particularly easily between the insulation displacement elements that are twisted relative to one another. As a result, an assembly process, e.g. during assembly, can be simplified, which reduces costs.

The fact that a distance between the two insulation displacement elements in the axial direction is at least five times the smaller of the widths between the blade pairs of the two insulation displacement elements advantageously greatly simplifies the assembly process with the cable. Because the distance is then sufficiently large to be able to easily thread a rigid cable with a rigid line into the two insulation displacement elements or to be able to thread them into their receiving openings.

According to a second aspect of the invention, a connector system is proposed. The connector system comprises an electrical connector as described above and a cable with an electrically conductive line and an insulating jacket surrounding the line, the cable being inserted into the two insulation displacement elements in the connection area and being electrically contacted and mechanically held there.

The proposed connector system is particularly robust and stable with respect to thermal loads and vibration loads, since electrical contact is always guaranteed. Due to the twisting of the two insulation displacement elements against one another, the cable cannot be easily detached from the connector when the amplitude of a vibration is parallel to one insulation displacement element, since it is then particularly good against the cutting edges of the other insulation displacement element -Elements is pressed.

The cable can have, for example, a rigid wire made of a metal as the electrical line and can comprise, for example, copper or aluminum or iron or alloys of these metals. The line can also be formed from a plurality of individual strands, as a result of which the line is somewhat more flexible and easier to bend, viewed transversely to its direction of extension.

The insulating jacket can be formed from an electrically insulating plastic, for example. It can be placed around the line in such a way that the line can move at least slightly relative to the insulating jacket. However, the insulating jacket can also be applied to the electrical line as a type of coating, such as wire for the manufacture of electrical coils.

The fact that the cable is inserted into the two receiving openings of the two insulation displacement elements in such a way that at least one cutting edge of each insulation displacement element cuts through the insulating jacket of the cable up to the line and the line is electrically contacted is advantageously a particularly safe causes electrical contact between the line and the connector. The connector system can be produced effortlessly and with little effort, since it is not necessary to strip the cable before the connector is fitted. A crimping process and its quality monitoring can also advantageously be dispensed with. By cutting into the insulating jacket, the cable is also advantageously fixed along the axial direction by a positive fit between the insulating jacket and/or the line on the one hand and the cutting edges on the other. Long-lasting, reliable contacting can thus be produced easily and very cost-effectively. Particularly in the case of lines that have aluminum, an aluminum oxide layer that is not a good electrical conductor can be severed by scratching the line when the connection is made.

character list

Further features and advantages of the present invention will become apparent to those skilled in the art from the following description of exemplary embodiments, which, however, are not to be construed as limiting the invention, with reference to the accompanying drawings.

• 1: eine schematische Darstellung eines Steckverbinders aus dem Stand der Technik;
• 2: eine schematische perspektivische Ansicht eines Steckverbinders gemäß der Erfindung;
• 3a: eine schematische perspektivische Ansicht eines Steckverbindersystems gemäß der Erfindung in einem ersten Zustand bei der Montage eines Kabels;
• 3b: eine schematische perspektivische Ansicht eines Steckverbindersystems gemäß der Erfindung in einem zweiten Zustand nach Abschluss der Montage des Kabels.

Show it

• 1 : a schematic representation of a connector from the prior art;
• 2 Fig. 1: a schematic perspective view of a connector according to the invention;
• 3a 1: a schematic perspective view of a connector system according to the invention in a first state during assembly of a cable;
• 3b Fig. 1: a schematic perspective view of a connector system according to the invention in a second state after the assembly of the cable has been completed.

1 shows an electrical connector 1 in insulation displacement technology from the prior art. The electrical connector 1 has a contact body 2 for making electrical contact with a mating contact, not shown here. The contact body 2 has a contact section 3 for making electrical contact with the mating contact and a connection area 4 for making electrical and mechanical contact with a cable (not shown here). The connection area 4 extends along a longitudinal axis A, the longitudinal axis A defining an axial direction. Directions transverse or perpendicular to the longitudinal axis A can be referred to as the radial direction.

A first insulation displacement element 10 is arranged in the connection area 4 . The first insulation displacement element 10 has two opposite cutting edges 11a, 11b. The two cutting edges 11a, 11b of the first insulation displacement element 10 define a first receiving opening 12 transversely to the longitudinal axis A for receiving the cable (not shown here), the first receiving opening 12 pointing outwards. The term "outwards" is to be understood here as pointing in a direction away from the longitudinal axis, ie a radial direction.

The cable, not shown here, can be inserted between the two cutters 11a, 11b together with an insulating jacket surrounding an electrical conductor of the cable. The receiving opening 12 tapers from the opening side to its first root 14 (ie from top to bottom in the figure). As a result, the insulating jacket is scored and severed by means of at least one of the cutting edges 11a, 11b, so that this cutting edge 11a, 11b can electrically contact the electrical conductor.

However, only a single insulation displacement element 10 is provided in the connector 1 shown. When the cable moves, e.g. due to thermal stress or vibrations, it may be possible that the cable - not shown here - moves upwards in the figure, in the direction of the receiving opening 12, and that the electrical and/or mechanical contact is lost.

2 shows an embodiment of a connector 1 according to the invention. The connection area 4 of the connector 1 extends along a longitudinal axis A, the longitudinal axis A defining an axial direction. Directions transverse or perpendicular to the longitudinal axis A can be referred to as the radial direction. In the exemplary embodiment shown, the contacting section 3 and the connection area 4 are arranged directly one after the other, viewed along the longitudinal axis A. They both extend along the longitudinal axis A.

Two insulation displacement elements 10 , 20 are arranged in the connection area 4 . A first insulation displacement element 10 and a second insulation displacement element 20. The two insulation displacement elements 10, 20 are spaced apart from one another in the axial direction, with a distance D between them. The two insulation displacement elements 10, 20 are connected to one another via an intermediate element 13. The intermediate element 13 extends here parallel to the longitudinal axis A. The intermediate element 13 can be designed, for example, as a metal strip. It may be in the form of a tab. The two receiving openings 12, 22 can be designed in such a way that they are aligned with one another at least in sections when viewed along the longitudinal axis A, so that when a cable is installed, the cable can run straight in a direction parallel to the longitudinal axis A, i.e. without bending transversely to the longitudinal axis A .

The first insulation displacement element 10 has two opposite cutting edges 11a, 11b and the second insulation displacement element 20 also has two opposite cutting edges 21a, 21b. The two cutting edges 11a, 11b of the first insulation displacement element 10 define, transversely to the longitudinal axis A, a first receiving opening 12 for receiving a cable (not shown here) (see FIG 3a and 3b) , wherein the first receiving opening 12 faces outwards - it faces upwards in the figure. In the same way, the two cutting edges 21a, 21b of the second insulation displacement element 20 define a second receiving opening 22 transversely to the longitudinal axis A for receiving the same cable, not shown here, the second receiving opening 22 also pointing outwards - in the present case figure to the left. Thus, the two receiving openings 12, 22 of the two insulation displacement elements 10, 20 are rotated relative to each other by an angle α about the longitudinal axis A. In the present exemplary embodiment, the angle α is 90°. The angle α can be in a range between 20° and 160°, preferably between 40° and 140° and very particularly preferably between 60° and 120°. This non-parallel alignment of the two receiving openings 12, 22 of the two clamping-cutting elements 10, 20 prevents movement of the cable, not shown here, from moving the cable along one of the directions of one of the receiving openings 12, 22 increased wear at the contact points between the cable and the sheaths 11a, 11b, 21a, 21b. Advantageously, this also prevents the cable from slipping out of both clamping/cutting elements 10, 20 or losing electrical contact when moving in one direction.

The first receiving opening 12 has a first height H1 which extends outwards from its first root 14 to the opening of the receiving opening 12 . In the illustrated embodiment, the first root 14 is that point which is furthest away from the outward opening of the first receiving opening 12 through which the cable is inserted. Similarly, the second receiving opening 22 has a second height H2 and a second root 24.

The first receiving opening 12 has a first width B1. In the exemplary embodiment shown, this is defined by the distance between the two cutting edges 11a, 11b in that section of the first clamping/cutting element 10 in which a fully assembled cable is fixed. In the exemplary embodiment shown, the receiving opening 12 has two different areas: an insertion area which is open to the outside, has a large width and acts in the manner of an insertion funnel. This is followed inwardly (that is to say towards the longitudinal axis A) by a cutting region. The width is greatly reduced in this cutting area, so that the cutting edges 11a, 11b can cut through an insulating jacket of an inserted cable and score the cable so that it is electrically contacted and mechanically held. In the exemplary embodiment shown, the cutting edges 11a, 11b run essentially parallel to one another in this cutting area and end in a U-shape in the first root 14 of the receiving opening 12. The first width B1 is thus determined in the cutting area. If the cutting edges 11a, 11b are not parallel in the cutting area, the Averaging the widths in the cutting area to determine the first width B1. Similarly, the second receiving opening 22 has a second width B2.

The distance D between the two insulation displacement elements 10, 20 in the axial direction can be at least 3 times, preferably at least 5 times and most preferably at least 7 times the smaller of the widths B1, B2 between the cutting edges - pairs 11a, 11b; 21a, 21b of the two insulation displacement elements 10, 20. The distance D can, for example, be at most 100 times, preferably at most 30 times and very particularly preferably at most 10 times the smaller of the widths B1, B2 between the pairs of cutting edges 11a, 11b; 21a, 21b of the two insulation displacement elements 10, 20.

The connection area 4 with the two clamping-cutting elements 10, 20 can be produced in one piece. The connection area 4 can be produced, for example, as a stamped and bent part. As a material, it can be formed from a metal sheet. In the exemplary embodiment shown, the connection area 4 extends to a housing of the contacting area 3, into which, for example, a mating contact (not shown here) can be inserted. However, the connection area 4 at least extends between the two clamping/cutting elements 10, 20 and then includes the two clamping/cutting elements 10, 20 and the intermediate element 13.

It is also possible for the connector 1 to be produced in one piece with its contact body 2 , the contact area 3 and the connection area 4 . The connector 1 can, for example, be manufactured as a stamped and bent part. As a material, it can be formed from a metal sheet.

The mating contact, not shown here, can be a pin or a blade of a male connector, for example, and can be plugged into the contact body 2 of the connector 1, for example. However, the mating contact can also be a through hole in a printed circuit board, for example, into which one end of the contact body 2 is pressed as a press-in connection pin.

In principle, it is of course possible for the connection area 4 to be tilted relative to the contacting section 3, for example bent by 30° to 150°, for example by 45° or by 60° or by 90° or by 105° or by 120° or by 135° ° kinked. In this case--not shown here--the longitudinal axis A does not run parallel or even identically to a further longitudinal axis of the contacting section 3. Nevertheless, the functionality of the invention is maintained even in such a kinked case. The longitudinal axis A (of the connection area 4) can, for example, correspond to an axis along which a cable 30 to be inserted into the two clamping/cutting elements 10, 20 runs in the assembled state (see FIG 3b) .

3a shows a connector system 100 in a first state during assembly. The connector system 100 has a connector 1, as is shown, for example, in 2 is shown. Furthermore, a cable 30 with an electrically conductive line 32 and an insulating jacket 31 surrounding the line 32 is provided. The cable 30 is assembled into the two insulation displacement elements 10, 20 by being inserted into the two receiving openings 12, 22, preferably in a radially inward direction.

3b shows a second state of the connector system 100. Here the cable 30 in the connection area 4 is introduced into the two insulation displacement elements 10, 20 and is electrically contacted and mechanically held there. The cable runs parallel to the longitudinal axis A, since the two receiving openings 12, 22 are aligned with one another in the direction in which the cable 30 extends.

In this case, at least one cutting edge 11a, 11b, 21a, 21b of each insulation displacement element 10, 20 has severed the insulating jacket 31 of the cable 30 down to the line 32 and makes contact with the line 32 electrically. For example, the lead 32 may be formed from a plurality of electrically conductive strands.

However, the line 32 can also consist of an electrically conductive individual line, and the insulating jacket 31 can be implemented as a coating, which conducts electrical current worse by several orders of magnitude than the individual line.

The height of the two cutting pairs 11a, 11b and 21a, 21b is at least 50%, preferably at least 75% and most preferably at least 100% of the diameter of the line 32. This height is to be understood as the distance from the respective Root 14, 24 extends to that section at which the cutting edges 11a, 11b or 21a, 21b move away from one another in order to form the insertion funnel of the receiving openings 12, 22.

Claims (8)

Electrical plug connector with a contact body (2) for making electrical contact with a mating contact, the contact body (2) having: - a contacting section (3) for electrical contact clocking of the mating contact and -- a connection area (4) for electrical and mechanical contacting of a cable (30), wherein the connection area (4) extends along a longitudinal axis (A) which defines an axial direction, wherein in the connection area (4) two insulation displacement elements (10, 20) are arranged, each having two opposite cutting edges (11a, 11b, 21a, 21b), the two cutting edges (11a, 11b, 21a, 21b) of an insulation displacement element (10, 20) each define a receiving opening (12, 22) pointing outwards transversely to the longitudinal axis for the cable (30), the two receiving openings (12, 22) of the two insulation displacement elements (10, 20) relative to one another are twisted by an angle (α) about the longitudinal axis (A), the angle (α) being in a range between 40° and 140°. Electrical connector after claim 1 , wherein the connection area (4) is formed in one piece. Electrical connector after claim 1 or 2 , wherein the electrical connector (1) is formed in one piece. Electrical connector after claim 1 or 2 , wherein the electrical connector (1) is manufactured as a stamped and bent part. Electrical connector according to one of the preceding claims, wherein the two insulation displacement elements (10, 20) are spaced from each other in the axial direction. Electrical connector according to the preceding claim, wherein a distance (D) between the two insulation displacement elements (10, 20) in the axial direction is at least five times the smaller of the widths (B1, B2) between the pairs of blades ( 11a, 11b; 21a, 21b) of the two insulation displacement elements (10, 20). Connector system comprising: - An electrical connector (1) according to any one of the preceding claims, - A cable (30) with an electrically conductive line (32) and an insulating jacket (31) surrounding the line, the cable (30) being introduced into the two insulation displacement elements (10, 20) in the connection area (4). and is electrically contacted and held there mechanically. Connector system according to the preceding claim, wherein the cable (30) is inserted into the two receiving openings (12, 22) of the two insulation displacement elements (10, 20) in such a way that at least one cutting edge (11a, 11b, 21a, 21b ) of each insulation displacement element (10, 20) cuts through the insulating jacket (31) of the cable (30) up to the line (32) and makes electrical contact with the line (32).

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