DE202011103484U1 - Contact element for an electrical connector device - Google Patents

Abstract

Device, wherein the contact element comprises: made of an electrically conductive material - a shaped first end section (102) - and a shaped, elongated receiving section (101) defining a longitudinal axis, for mechanical and electrical coupling or receiving of a mating contact element designed to be complementary to the contact element one with the electrical piercing device, - wherein the elongated receiving section extends from the first end section essentially cylindrical and wherein the first end section and the elongated, cylindrical receiving section are free of seams and cuts by material deformation of the electrically conductive material by means of a force acting at least predominantly parallel to the longitudinal axis are shaped and at least the receiving portion is hollow along the longitudinal axis.

Description

The invention relates to an elongate contact element for an electrical connector device.

The invention is based on a prior art, according to which electrical connector devices can basically be formed as a socket or plug and usually have a contact insert block, in which inserted elongated generic contact elements in the case of a plug as an electrical connector device as elongated pins and in the case of as Bush formed electrical connector device are designed as elongated contact sockets. Such electrical connector devices are particularly in the standards DIN VDE 0623 . IEC 60309-1, -2 and EN 60309-1, -2 described.

The contact elements used accordingly serve for the respective mechanical and electrical coupling with a complementary counter-contact element. An elongated contact pin is thus mechanically and electrically coupled with an elongated contact socket, d. H. the contact socket takes on the inside of the contact pin or picks up the contact pin on its outer circumference on the contact socket. The sections of a contact element which serve for coupling or for receiving a mating contact element are hereinafter and in the claims also referred to as receiving section.

Furthermore, such a contact element usually has a portion adjacent to the receiving portion or also spaced, which serves for the mechanical and electrical coupling or for receiving an electrical connection conductor.

The generic elongate contact elements thus consist essentially of electrically conductive material, conventionally of a metal.

The EP 1 783 868 relates to such, formed as an elongated contact pin contact element which is formed from a flat solid material by punching and bending and along the receiving portion has a substantially hollow cylindrical cross-section. Although the contact pin described there meets the requirements according to local description DIN VDE 0623 . EN 60309-2 and saves compared to hollow material made of solid material by machining or abrasive material removal hollow cylindrical pins and solid material contact pins, ie without a hollow cylindrical cross section, material. As according to EP 1 783 868 however, due to the contact pin bent from stamped sheet, edges abutting each other which must be connected by a tooth, wherein mushroom-shaped projections are formed on one edge, which engage in complementary recesses of the abutting other edge, may from the outside unwanted impurities and / or moisture in the edge interstices penetration.

It has been shown that in particular in such edge gaps penetrating and possibly remaining impurities and / or moisture can cause unwanted oxidations and / or corrosion, which in turn can lead to increased contact resistance during power transmission as a result.

An object of the invention is to counteract the aforementioned disadvantages effectively.

The solution according to the invention is given in a surprising way already by a contact element for an electrical connector device according to claim 1. Advantageous and expedient embodiments and developments are the subject of the dependent claims.

The invention therefore proposes for the solution of a contact element for an electrical connector device, which consists of an electrically conductive material, a shaped first end portion and a shaped, a longitudinal axis defining elongated receiving portion for the mechanical and electrical coupling or receiving a complementary to the contact element formed counter contact element the electrical connector device to mating connector device has, wherein the elongate receiving portion from the first end portion extends substantially cylindrical and wherein the first end portion and the elongated cylinder-like receiving portion by material deformation of the electrically conductive material by at least predominantly parallel to the longitudinal axis force acting force of seams and Cutting collars are formed and at least the receiving portion along the longitudinal axis is hollow.

Thus, according to the invention, for the first time, there is freedom from seams and freedom from material transitions and, consequently, a circumferential, ie. H. on the cylinder-like surface completely closed hollow cylinder-like receiving portion allows, without this purpose is to produce using cutting or abrasive material removal of a solid material.

Due to the freedom of material transitions including seams and cuts along the receiving portion, the unwanted ingress of contaminants and / or moisture is substantially reduced, and may even be completely avoided depending on the further design of the contact element. Furthermore, due to the hollow cylindrical design of the contact element is thus saved in any case weight compared to solid material contact elements and material compared to hollow material made of solid material by machining or abrasive removal of material hollow cylindrical pins.

In preferred embodiments it is provided that at least the elongated, hollow-cylindrical receiving section is formed by means of a deep drawing or extrusion process, in particular being formed from a flat material. Due to such a consumption-optimized production of the receiving portion along its elongated extent completely closed circumferentially and leads to a weight saving and material savings in contrast to solid-material contact elements and formed by Materialabtragende method contact elements. In particular, hollow-backward extrusion processes and hollow-forward extrusion processes have proven to be particularly suitable as extrusion processes.

Expediently, a connection device for mechanical and electrical coupling or for receiving an electrical connecting conductor is also formed on the first end section. The end opposite the first end portion on the elongated hollow cylindrical receiving portion may be open or closed. When using the above-mentioned preferred embodiments has proven to perform the application of a deep drawing or extrusion process such that this end is initially closed and optionally opened later. On the one hand, in this case, with the formation of a connection device on the first end section, a completely closed contact pin can be produced in a simple manner; on the other hand, a less complex deep-drawing or extrusion tool suffices to provide a first end section, to which a connection device can be formed with little effort.

In an expedient embodiment, it is provided for this purpose that the connection device formed on the first end section is formed by application of a material-removing method and / or a punch-bending method.

In a preferred embodiment, it is further provided that a connection device formed on the first end portion is mounted on this end portion, in particular screwed, riveted or added, in particular welded, soldered or otherwise attached.

In an alternative development, it is further provided that the connecting device formed on the first end section, the first end section and the receiving section are formed in one piece.

The invention will now be further described by way of preferred embodiments with reference to the accompanying drawings, in which further advantages and features of the invention will become apparent to those skilled in the art. In the drawings show:

1a to 1b A first embodiment of a contact element according to the invention,

2a to 2d a second embodiment of the invention based on the first embodiment;

3a to 3c a third embodiment according to the invention based on the first embodiment,

4a to 4d a fourth embodiment of the invention based on the first embodiment;

5a to 5d a fifth embodiment according to the invention,

6a to 6d a clamp spring in profile view, side view, top view and perspective, and

7A to 7B an exemplary connector assembly of two mating connector devices with screwless contact elements.

The following is first on the 1a to 1b Referring to a first embodiment of a contact element according to the invention for an electrical connector device (such as in 7A . 7B shown).

The contact element has an elongated receiving portion 101 and a first end portion 102 , wherein the receiving section 101 from the first end section 101 from substantially hollow cylindrical for mechanical and electrical coupling or receiving a complementary to the contact element formed, but not shown mating contact element extending with the electrical connector device to mating connector device. The elongated, hollow-cylindrical receiving portion 101 is here formed free of material transitions and formed of an electrically conductive material, as well as the first end portion 102 is formed from this electrically conductive material. That the first end section 102 opposite end 103 at the receiving portion 100 is closed.

The hollow cylinder-like receiving portion 101 is characterized by seam freedom and freedom of material transitions and is therefore circumferentially, ie completely closed on the cylinder-like surface.

like that 1a and 1b can be seen, is the elongated, hollow-cylindrical receiving portion 101 including the areas 102 and 103 formed from a flat material. In the illustrated embodiment, this is a circular flat material 100 has been used, from which the elongated, hollow-cylindrical receiving portion 101 including the areas 102 and 103 is formed by using a deep-drawing process. In an alternative embodiment of the invention, instead of a deep-drawing process z. B. also an extrusion molding process, preferably a hollow-backward extrusion process or a hollow-forward extrusion process can be used.

With application of the aforementioned preferred thermoforming or extrusion method, the first end portion 102 with a kind of circumferential collar 104 been trained. When deep drawing or extrusion of the "punch" to the hollow cylindrical inner shape of the receiving portion 101 from the side of the then first end section 102 Coming used here comes a less complex deep drawing or extrusion tool for providing such or similar first end portion 102 ,

Such or similar first end portion 102 with such or a similar type of circumferential collar 104 can already provide a molded together with the receiving portion of a piece connection device for mechanical and electrical coupling or for receiving an electrical connection conductor, wherein the connection conductor in this case z. B. is soldered to the collar.

In development of the embodiment according to 1a and 1b are in the embodiments according to 2a to 2d . 3a to 3c and 4a to 4d illustrated modified embodiments, in which with little effort at a first end portion 102 according to 1b or similar first end portion formed alternative connection means are mounted on the receiving portion.

The in the modified embodiments according to 2a to 2d . 3a to 3c and 4a to 4d illustrated elongated, hollow cylindrical receiving portions 101 including the first end section 102 and the end opposite this end portion 103 are preferably again from flat materials according to 1a made, from each of which the elongated, hollow-cylindrical receiving portion 101 including the areas 102 and 103 is suitably shaped by use of a deep-drawing process or an extrusion molding process.

According to embodiment according to 2a to 2d is at the first end portion 102 ( 2c . 2d ) a connection device for mechanical and electrical coupling or for receiving an electrical connection conductor is formed, which has a connection section 120 has.

As an option, this connection section 120 already be provided as a connection device. The illustrated connection section 120 is before ( 2a and 2 B ) by using a material-removing method of an electrically conductive solid material 115 ( 2a ) and then at the first end portion 102 at the receiving portion 101 mounted, z. B. soldered. It should be noted, however, that the connection section 120 Depending on the specific training principle also screwed, riveted or otherwise added, for. B. can be welded. An electrical connection conductor can thus be connected to the connection section 120 be fixed as a connection device for mechanical and electrical coupling or recording at this, z. B. be soldered.

As a special additional option according to 2d is provided that the exclusion device is designed in several parts and the exclusion device z. B. the connection section 120 and a clamping spring 129 has, which at the connection section 120 is attached.

The connection section 120 has this z. B. an attached contact surface 121 on which the connecting terminal to be connected for making an electrical contact is laid, and also a guide nose 122 equipped, which has a bevel and the contact surface 121 extended. The bevel on the one hand, the mounting of the clamping spring 129 to the connection section 120 on the other hand, simplifies and fulfills the function of a conductor guide (even if the clamping spring is not inserted), so that a connected connection conductor is safe, that is not sharp-edged or bent off from the connection section 120 can be carried away. In addition, the connection section 120 when used with a clamping spring appropriate with respect to the contact area 121 lying recess 123 , z. B. in the form of a milled groove for receiving a contact leg of the clamping spring 129 Mistake. A guide recess 124 , which in the connection section 120 is milled, serves z. B. to engage a conductor clamping extension of the clamping spring 129 while lateral support legs 125 fix this, with a clamping leg of the clamping spring 129 at the front 126 of the connection section 120 is created.

A possible, particularly preferred embodiment of a clamping spring 129 is in the 6a to 6d shown. This clamping spring 129 FIG. 12 illustrates a metal clamping spring formed by the use of a stamping-bending process, showing a clamping leg 7 and a plant leg 8th having. Both spring legs 7 . 8th are over a clamping leg 9 connected with each other. In the clamping leg 7 the clamping spring 129 is a clamp opening 6 recessed, which is a crossover of the clamping leg 7 and the plant leg 8th by means of a subsection 8b of the plant leg 8th allows. The clamping opening 6 the clamping spring 129 allows the introduction of conductor wires of a connecting conductor in the insertion direction E. The clamping leg 7 further, relative to the clamping leg 7 the clamping spring 129 , a ladder clamping extension substantially angled at a 90 degree angle 10 on, which in the direction of the plant leg 8th is aligned and its clamping surface 11 is oriented substantially in the manner of a clamping plate parallel to the surface. The conductor clamping extension 10 thus extends from the clamping leg 7 from in the insertion direction E of an electrically connected connection conductor. The conductor clamping extension 10 can continue with an additional clamping section 10b equipped, its clamping surface 11b relative to the clamping surface 11 of the conductor clamping extension 10 angled or curved.

In the training according 2d Thus, the multi-part formed at the first end portion connecting device is formed by applying a material-removing method and a punch-and-bend method.

According to embodiment according to 3a to 3c is at the first end portion 102 a connection device for mechanical and electrical coupling or for receiving an electrical connection conductor is formed, which is opposite to the 2 B to 2d modified designed connection section 130 has.

The connection section 130 indicates in a modification to the 2 B to 2d in particular no recess lying opposite the contact surface, and no guide recess and no lateral support leg and is therefore easier to produce in the shaping.

As an option, this connection section 130 already be provided as a connection device. The illustrated connection section 130 is before ( 3a and 2a ) by using a material-removing method of an electrically conductive solid material 115 ( 2a ) and then again at the first end portion 102 at the receiving portion 101 assembled. An electrical connection conductor can thus in turn be connected to the connection section 130 be fixed as a connection device for mechanical and electrical coupling or recording.

As another option, not shown, however, it may also be provided in this embodiment that the exclusion device is designed in several parts and the exclusion device z. B. in addition to the connection section 130 still has a clamping spring, which at the connection section 130 is attached.

According to embodiment according to 4a to 4d is at the first end portion 102 a connection device for mechanical and electrical coupling or for receiving an electrical connection conductor is formed, which is opposite to the 2 B to 2d alternatively modified designed connection section 140 has.

As an option, this connection section 140 in turn already be provided as a connection device. The illustrated connection section 140 is before ( 4a and 4b ) in a modification to the 2 B to 2d by applying a punch-bending method of an electrically conductive material, in particular flat material 116 ( 4a ) and then again at the first end portion 102 at the receiving portion 101 assembled. An electrical connection conductor can thus turn to the connection section 140 be fixed as a connection device for mechanical and electrical coupling or recording.

As a special additional option according to 4d is provided that the exclusion device is again designed in several parts and the exclusion device z. B. the connection section 140 and a clamping spring 129 has, which at the connection section 140 is attached.

The connection section 140 has expediently similar to the connection section 120 to 2 B to 2d a contact surface 141 on which the connecting terminal to be connected for making an electrical contact is laid, and also a guide nose 142 which one Has bevel and extends the contact surface. The bevel on the one hand, the mounting of the clamping spring 129 to the connection section 140 on the other hand, simplifies and fulfills the function of a ladder guide (even if the clamping spring is not used). In addition, the connection section has 140 a guide, which z. B. to engage a conductor clamping extension of the clamping spring 129 serves while lateral support legs 145 fix this, which in turn is a clamping leg of the clamping spring 129 at the front of the connection section 140 can be created. The lateral support legs 145 However, z. B. also for direct fixing of an electrical connection conductor at the connection section 140 be used, for. B. by crimping, especially if the connection section 140 already provides the one-piece, connection device.

In a further alternative embodiment according to 5a to 5d It is further provided that the connecting device formed on the first end portion and the receiving portion may be formed in one piece.

According to embodiment according to 5a to 5d is at the first end portion 102 a connection device for mechanical and electrical coupling or for receiving an electrical connection conductor is formed, which has a connection section 150 has.

As an option, this connection section 150 in turn already be provided as a connection device.

As a special additional option according to 5d is provided that the exclusion device is again designed in several parts and the exclusion device z. B. the connection section 150 and a clamping spring 129 has, which at the connection section 150 is attached.

The connection section 150 has expediently similar to the connection section 140 to 4b to 4d a contact surface 141 on which the connecting terminal to be connected for making an electrical contact is laid, and also a guide nose 142 , which has a bevel and extends the contact surface. The bevel on the one hand, the mounting of the clamping spring 129 to the connection section 150 on the other hand, simplifies and fulfills the function of a ladder guide (even if the clamping spring is not used). In addition, the connection section has 150 a guide, which z. B. to engage a conductor clamping extension of the clamping spring 129 serves while lateral support legs 145 fix this, which in turn is a clamping leg of the clamping spring 129 at the front of the connection section 150 can be created. The lateral support legs 145 However, in turn z. B. also for direct fixing of an electrical connection conductor at the connection section 150 be used, for. B. by crimping, especially if the connection section 150 already provides the connection device.

In modification to the 4b to 4d as well as all other embodiments described above, however, the illustrated connection section 150 before ( 5a ) together with the elongated, hollow-cylindrical receiving portion 101 including the areas 102 and 103 formed from one piece, in particular from a piece of flat material 117 ,

In the illustrated embodiment, this is a flat material 117 used, which for forming the receiving portion 101 including the areas 102 and 103 a first area 118 owns, which turns to one side in a second area 119 for shaping the connection section 150 Flat material extension 119 continues.

The first area 118 is expedient turn substantially circular, so that from this by application of a deep-drawing process or extrusion process of the elongated, hollow-cylindrical receiving portion 101 including the areas 102 and 103 is malleable, and then from the extension area 119 by applying a punch-bending method of the terminal section 150 can be trained.

An electrical connection conductor can thus again directly at the connection section 150 be fixed as a connection device for mechanical and electrical coupling or recording.

It is obvious that in all the above-described embodiments, the first end portion 102 opposite end 103 on the elongated, hollow cylindrical receiving portion also open, z. B. may be to form a contact socket. The opening can in this case after formation of the receiving portion 101 done separately or during the training of the receiving section 101 if z. B. during deep drawing or extrusion of the "punch" to the hollow cylindrical inner shape of the receiving portion 101 from the side of the then first end section 102 opposite side is used coming. In this case, the first end section 102 also be closed depending on the specific tool training.

It is obvious to a person skilled in the art that connection devices are also included within the scope of the invention lie where to use for connecting an electrical conductor other techniques than clamping, soldering and crimping, such. B. screwing.

In particular, when using a deep-drawing process or extrusion process can thus by the consumption-optimized manufacturing process in an efficient manner a completely closed hollow contact element, while saving raw material as no solid contact element obtained that no visible or invisible transitions, cutting joints or the like. having in traditional manufacturing processes such. As stamping-bending technique, roll technology, or the like, production-related occur. The contact element according to the invention can be made completely tight by avoiding transitions, etc., so that from the outside no contamination, moisture or the like. can penetrate. Unwanted oxidations or corrosion, which lead to increased contact resistance during power transmission, can thereby be avoided.

As can be seen from the above description, the embodiments can vary considerably. Combinations such. B. elongated hollow receiving portion including a first end portion, from which the receiving portion extends to a first end portion opposite the end, with mounted, for. B. welded or riveted, connection device or z. B. contact elements as a complete deep-drawn optionally with subsequent cutting (or punching) and bending sequence are possible to form a hollow contact element according to the invention

The contact elements according to the invention are thus particularly suitable for electrical connector devices which may be formed as a plug but also as a socket and have a contact insert block, in which these contact elements are to be used, and which in particular in the standards DIN VDE 0623 . IEC 60309-1, -2 and EN 60309-1, -2 are described.

In the pending 7a and 7b is an example of a connector assembly 17 from two mating connector devices, ie shown with a plug and a coupling, in which screwless contact elements, manufactured in the example shown in the prior art, are introduced. The connector assembly 17 is here for two-sided connection to a conductor 2 prepared, being 7A Connector devices with opened clamping openings 6 of clamping legs 7 of clamping springs 5 shows, and 7B closed clamping openings 6 shows.

The connector assembly 17 has as a connector device, a coupling device with a tubular coupling housing 18 and as another mating connector device, a connector device having a connector housing 19 on, which are both inserted into each other and each formed by complementary contact elements 1 ie contact sockets 1 and contact pins 1 which mesh with each other, are electrically connected to each other. It should be mentioned that in the views 7A and 7B only one contact element is shown within a plug connection device for reasons of clarity, with more contact pins or contact sockets are usually included in connector devices with.

Both housings 18 . 19 each comprise a cylindrical contact element carrier 20 , with individual receiving chambers for receiving further contact elements 1 is formed, made of insulating material and with the coupling housing 18 or the connector housing 19 latched or otherwise connectable. The number of respective receiving chambers for the sitftartigen or female contact elements 1 in each cylindrical contact element carrier 20 depends on the purpose and can z. B. either three receiving chambers (two phase contacts and a protective conductor contact), or four receiving chambers (three phase contacts and a protective conductor contact), or five receiving chambers (three phase contacts, a zero conductor contact and a protective conductor contact). The two housings 18 and 19 have a protective part in the form of a hood 22 for inserting a conductor 2 and a rotatably operable strain relief device in the form of a clamping sleeve 23 on. On the clutch housing 18 is a hinged lid 24 attached to the contact socket 1 covers and protects against splashing water when the clutch 18 out of engagement with the plug 19 is.

How out 7A and 7B As can be seen, the contact surfaces are sufficient 4 and the clamping springs 5 the screwless terminals each in individual receiving chambers of the contact element carrier 20 into it. The cantaktelementträger 20 is provided with access openings, through each of which a locking slide 21 extends as a contact opener. Further access openings lead to the contact surfaces 4 the contact elements 1 , The locking slide 21 has a recess 21b on, in which the clamping spring 5 can intervene. The locking slide 21 has the function of a depressing tool, which can take two positions, namely a release position of the clamping spring, as in 9B shown, and a depressing position of the clamping spring, as in 9A shown at the recess 21b in the locking slide 21 the clamping leg 9 the clamping spring 5 depresses and the clamping opening 6 opens, so that the free conductor wires 2 B in the terminal opening 6 can be pushed. The two mentioned positions of the locking slide 21 are determined by stops on respective shoulders of the contact element carrier 20 issue. To the locking slide 21 to be able to move easily between its two openings, an actuating opening is provided, on which engage, for example, a screwdriver and can push the locking slide back and forth.

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• EP 1783868 [0006, 0006]

Cited non-patent literature

• DIN VDE 0623 [0002]
• IEC 60309-1, -2 [0002]
• EN 60309-1, -2 [0002]
• DIN VDE 0623 [0006]
• EN 60309-2 [0006]
• DIN VDE 0623 [0061]
• IEC 60309-1, -2 [0061]
• EN 60309-1, -2 [0061]

Claims (9)

Contact element for an electrical connector device, wherein the contact element comprises: an electrically conductive material - a shaped first end section ( 102 ) - and a shaped, a longitudinal axis defining, elongate receiving portion ( 101 ), for mechanically and electrically coupling or receiving a mating contact element complementary to the contact element of a connector device to be mated with the electrical connector device, wherein the elongated receiving section extends substantially cylindrically from the first end section and wherein the first end section and the elongated, cylinder-like Receiving portion are formed by material deformation of the electrically conductive material by means of at least predominantly parallel to the longitudinal axis force acting force free of seams and cutting joints and at least the receiving portion along the longitudinal axis is hollow. Contact element according to claim 1, further characterized in that at least the elongated, hollow-cylindrical receiving portion by means of a deep-drawing or extrusion molding process, is formed, in particular of a flat material is formed. Contact element according to claim 1 or 2, further characterized in that at the first end portion, a connection device for mechanical and electrical coupling or for receiving an electrical connection conductor is formed. Contact element according to claim 3, further characterized in that the connecting device formed on the first end portion is mounted on the end portion, in particular screwed, riveted or attached, in particular welded, soldered or otherwise attached. Contact element according to claim 3 or 4, further characterized in that the exclusion device is designed in several parts. Contact element according to claim 3 to 5, further characterized in that the exclusion device comprises a clamping spring ( 129 ) owns. Contact element according to claim 3, further characterized in that the connecting device formed on the first end portion and the receiving portion are formed in one piece. A contactor according to any one of claims 3 to 7, further characterized in that the terminal means formed at the first end portion is formed by applying a material removing method and / or a punching and bending method. Contact element according to one of claims 1 to 8, further characterized in that the end opposite the first end portion is open or closed at the elongated, hollow cylindrical receiving portion.

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