DE202022002776U1 - Electrical cable or electrical line designed with a plug-in contour for direct plugging into a mating connector - Google Patents

Abstract

Electrical line (20), in particular an electrical stranded conductor (20), having a line end (23) which forms a plug-in section (21) which has at least one flat surface section (22a, 22b), and at least one directly on the surface section (22a, 22b ) Applied and connected to this contact lamella strip (30), wherein the contact lamella strip (30) has a plurality of (elastically) resilient contact lamellae (31) protruding from it.

Description

The invention relates to electrical cables or electrical lines designed with a plug-in contour for direct plugging into a plug-in socket, e.g. on a mating plug, an interface, a contact socket or a plug.

In the prior art there is no uniform terminology for plugs and sockets or male contacts and female contacts. In the terminology of the present invention, either male or female contacts can be used in a plug or socket. Male contacts are generally non-resilient contact geometries such as contact pins, contact pins, flat contacts or the like. Female contacts represent resilient contacts in which there is at least one resilient contact element which is involved in contacting a mating contact.

A plug-in connection is realized by a plug and a mating connector, with resilient contacts corresponding to one another or interacting with one another and non-resilient contact parts being optionally provided in the respective plugs and mating connectors.

Furthermore, a large number of connection solutions are known in the prior art for connecting an electrical contact element to an electrical line, e.g. a stranded conductor. Conventional techniques such as soldering, welding, crimping and the like are not discussed in this disclosure, since these methods are adequately described in the prior art and in the IEC 60325 series of standards.

The EN 60352-2 contains requirements, tests and application notes for solderless crimp connections made with stranded wire conductors from 0.05 mm ² to 10 mm ² cross-section or with solid conductors from 0.25 mm to 3.6 mm diameter and with suitable uninsulated or pre-insulated crimp barrels.

Significantly larger cable cross sections cannot currently be easily connected to a contact element in an efficient and cost-effective manner. Not only the manufacturing technology, but also the contact geometry or the contact design is complex and expensive.

Increasingly, the components of alternative drives in automotive engineering are designed to be pluggable in terms of their electrical contacts due to the ease of assembly and servicing. The plug connections are subject to the highest demands in terms of electrical contact properties, resilience, tightness and installation space.

The DE 102013004708 A1 relates to an electrical stranded conductor made of copper for parallel and/or serial contacting of round plug-in contacts with a line cross-section, at least one section of the stranded conductor having a section with a reduced cross-section and a cylindrical round plug-in contact socket or a cylindrical round plug-in contact pin being welded to this section.

Another significant problem in the prior art is the use of copper as a connecting means, since copper can be connected to a contact element by welding only with difficulty or not reliably, as is required in the automotive industry.

Will e.g. B. the detachable plug contacts made of a first material, which differs from copper or has an alloy in which copper is present only to a reduced extent, there is a particular problem in connecting the plug contacts with the copper conductor.

In the prior art, crimp connections are therefore primarily used in order to establish the connection securely.

The present invention is therefore based on the object of providing a solution for making contact between an electrical interface and an electrical line in a simple and cost-effective manner.

This object is achieved by the combination of features according to protection claim 1.

1. a. Umformen, insbesondere Pressumformen der elektrischen Leitung am Leitungsende unter Ausbildung eines (vorzugsweise verdichteten) Steckabschnittes mit wenigstens einem flachen Flächenabschnitt an diesem Leitungsende,
2. b. Bereitstellen eines Kontaktbandes (Kontaktlamellenbandes), wobei das Kontaktband mehrere aus dem Kontaktband hervorstehenden federnden Kontaktlamellen aufweist und
3. c. Aufbringen und Verbinden des Kontaktbandes auf dem Flächenabschnitt.

A basic idea of the invention is to modify a conventional electrical line (cable) in such a way that the line itself or the line end is designed as a plug-in contour. A method is therefore proposed for producing such a plug-in contour at a line end of an electrical line, in particular a stranded line, with the following steps:

1. a. Forming, in particular press forming, of the electrical line at the end of the line to form a (preferably compacted) plug-in section with at least one flat surface section on this line end,
2. b. Providing a contact band (contact lamella band), wherein the contact band has a plurality of resilient contact lamellae protruding from the contact band and
3. c. Applying and connecting the contact strip to the surface section.

Furthermore, the term electrical line is also an electrical conductor such. B. to understand a rigid power rail. Instead of compacting or reshaping an electrical line, it is also conceivable to use a (solid) busbar and then to carry out steps b) and c) on the surface of the busbar.

The contact strip is to be applied in such a way that the contact lamellas protrude on the top side opposite the connection side and can act there as resilient lamellas when plugged together with a mating plug element.

It is further preferred if the electrical line has a substantially round cross-sectional shape in the adjacent non-formed area of the line adjoining the formed area. Round in the sense of the present invention is a cross-sectional shape of typical round lines, which is not always perfectly round but approximately round.

In a further advantageous embodiment, it is provided that a substantially cuboid line section is formed, preferably compressed, during the forming process. This should be done in such a way that the strands of the stranded conductor are locally baked and pressed together, which can be achieved in particular by a compacting process.

It is therefore also advantageous if the end of the line is processed by means of compaction and, in particular, is brought into a shape in which the plug-in section is formed with a flat upper side and a flat lower side which is essentially parallel thereto. This provides a simple plug-in contour in a basic form suitable for a plug-in process.

In a further advantageous embodiment it is provided that such a contact strip, contact lamella strip, is provided, in which several parallel arranged contact lamellas are provided and the contact lamella strip is applied to one of the surface sections at the end of the line oriented in such a way that the parallel arranged contact lamellae either along or transversely, are oriented in particular 90° transversely to the direction in which the cable extends.

The present invention relates to an electrical line, in particular an electrical stranded conductor, having a line end which forms a plug-in section which has at least one flat, in particular planar surface section, and at least one contact lamella strip applied directly to the surface section and connected to it, the contact lamella strip comprising several has protruding (elastic) resilient contact lamellae.

In an advantageous embodiment of the line, it is provided that the electrical line has a substantially round cross-sectional shape in the adjacent non-formed area of the line adjoining the plug-in section at the end.

Also advantageous is a solution in which the contact lamella strip has a web (32) on at least one edge area, on which the several contact lamellas are connected on one side and the other (opposite) end of the contact lamellas is designed as a free end. The contact lamellae can advantageously be bent like a spoon tip, so that the contact point of the respective contact lamella lies approximately in the center of the surface section in the direction of the contact lamella extension and the ends of the contact lamellae end on or nearer to the surface sections. To clarify the preferred course of the lamellae, reference is made to the figure in the area of the description of the exemplary embodiments.

In principle, however, other slat shapes are also conceivable. In any case, according to the concept of the invention, it is advantageous if several, in particular 3, 4, 5, 6 or 7, lamellae are arranged next to one another.

An alternative embodiment provides that two opposing surface sections are formed on the plug-in sections and a contact lamella strip connected to it is preferably applied and fastened to each surface section. The alignment of the contact lamellae can be mirror-inverted or opposite.

In an advantageous configuration of the cable, it is also provided that at least one contact lamellar strip protrudes laterally and/or at the front with a projection beyond the outer contour of the plug-in section, so that the respective projection creates a contact or stop surface for interaction with a counter-surface on a Mating is formed according to shaped, corresponding mating connector. With a defined overhang, joining and plugging together with the mating plug element can be optimized.

The contact strip is advantageously connected in a materially bonded manner, particularly preferably at a plurality of connection points.

The concept of the invention is particularly suitable for electrical lines that have a cable sheath. Then, in the method, before compacting or generally forming, the cable jacket is removed in a defined end section and the remaining cable jacket can also serve as a stop for determining the insertion depth.

• 1 eine erfindungsgemäßer Leitungsabschnitt mit einer Steckkontur;
• 2 eine alternative Ausführungsform einer erfindungsgemäßen Leitung mit einer Steckkontur;
• 3 eine stirnseitige schematische Ansicht auf eine erfindungsgemäße Steckkontur;
• 4 eine Aufsicht auf die Ausführung analog 3;
• 5 eine Aufsicht und Seitenansicht eines alternativen Kontaktlamellenbandes.

Other advantageous developments of the invention are characterized in the dependent claims or are presented in more detail below together with the description of the preferred embodiment of the invention with reference to the figures. Show it:

• 1 a line section according to the invention with a plug-in contour;
• 2 an alternative embodiment of a line according to the invention with a plug-in contour;
• 3 an end-side schematic view of a plug-in contour according to the invention;
• 4 a supervision of the execution analogously 3 ;
• 5 a top view and side view of an alternative contact blade strip.

The figures are merely schematic by way of example. The same reference numbers in the figures indicate the same functional and/or structural features.

In the 1 and 2 two exemplary embodiments of a plug-in line 20 are shown. A section of an electrical line 20 with the line end 23 , which forms a plug-in section 21 , is shown in each case.

The male portion 21 has in the two 1 each have a parallelepipedal shape and upper and lower flat surface portions 22a, 22b diametrically opposed to each other.

On the respective upper surface section 22a a contact lamella strip 30 is materially attached, as in FIG 4 to recognize connected at several materially bonded connection points 36. It can also be seen that the contact lamella strip 30 has several (in the 1 and 2 each has three) protruding from this (elastic) resilient contact blades 31. The contact lamellae 31 protrude upwards, so that during the plugging process they are provided on a counter-contour for resilient contacting. Due to the resilient properties, a contact force is obtained depending on the number of contact lamellae and their spring properties.

Furthermore, in the 1 and 2 It is easy to see that the electrical line 20 has a substantially round cross-sectional shape in the non-formed region 24 of the line 20 adjoining the plug-in section 21 at the end and is designed with a cable jacket 26 .

In the 5 an embodiment of a contact lamella strip 30 is shown. This has a web 32 at the edge on at least one edge area, on which the multiple contact lamellae 31 are connected on one side and the other (opposite) end 34 of the contact lamellae 31 is designed as a free end. In this way, resilient contact arms are obtained which, moreover, have a shape as can be seen in the view shown alongside.

In the 3 two opposing surface sections 22a, 22b are formed on the plug-in section 21 and on each surface section 22a, 22b a contact lamella strip 30 connected thereto is applied and fastened, the contact lamellae being arranged in opposite directions with their orientation. A mirror-image arrangement would be possible as an alternative. It can also be seen that the contact lamella strip 30 protrudes laterally with a projection 35 beyond the outer contour of the plug-in section 21, so that the respective projection 35 forms a contact and stop surface for interaction with a mating surface on a correspondingly shaped mating connector for mating is. Such a design is also in the 1 and 2 recognizable.

The contact lamella strip 30 shown has in each case a plurality of (elastically) resilient contact lamellas 31 protruding from it.

The orientation of the contact blades in the execution of 1 takes place parallel to the line extension direction L and in 2 at a 90° angle across it.

QUOTES INCLUDED IN DESCRIPTION

This list of documents cited by the applicant was 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.

Patent Literature Cited

• DE 102013004708 A1 [0008]

Non-patent Literature Cited

• DIN EN 60352-2 [0005]

Claims (6)

Electrical line (20), in particular an electrical stranded conductor (20), having a line end (23) which forms a plug-in section (21) which has at least one flat surface section (22a, 22b), and at least one directly on the surface section (22a, 22b ) Applied and connected to this contact lamella strip (30), wherein the contact lamella strip (30) has a plurality of (elastically) resilient contact lamellae (31) protruding from it. Electrical line (20) after claim 1 , characterized in that the electrical line (20) has a substantially round cross-sectional shape in the adjacent non-formed region (24) of the line (20) adjoining the plug-in section (21) at the end. Electrical line (20) after claim 1 or 2 , characterized in that the contact lamella band (30) has a web (32) at the edge on at least one edge area, on which the plurality of contact lamellas (31) are connected on one side and the other (opposite) end (34) of the contact lamellas (31) as a free end is formed. Electrical line (20) according to one of Claims 1 until 3 , characterized in that two opposing surface sections (22a, 22b) are formed on the plug-in section (21) and on each surface section (22a, 22b) a contact lamella strip (30) connected thereto is applied and fastened. Electrical line (20) according to one of Claims 1 until 4 , characterized in that at least one contact lamella strip (30) with a projection (35) projects laterally and/or at the front beyond the outer contour of the plug-in section (21), so that the respective projection (35) creates a contact and stop surface for interaction with a Mating surface is formed on a correspondingly shaped mating connector for mating. Electrical line (20) according to one of Claims 1 until 5 , characterized in that the line has a line jacket (26).

Images