DE2922067A1 - ELECTRICAL CONTACT AND MANUFACTURING PROCESS - Google Patents

Description

The invention relates to a novel electrical contact and a novel manufacturing method for this contact. In particular, the invention relates to an electrical contact holder, which is particularly advantageous for producing an electrical Contact on the type of US-PS 37 25 844 is, which is called "brush contact" in the following.

Prior electrical contacts of this type are known and typically comprise a number of fine, axially aligned wires (sometimes called "brush wires") extending from one end of a holder designed to accept a lead to a socket extend at the other end. In such applications, of which

one disclosed in the aforementioned patent is the holder made of a cylindrical material, with holes drilled from both ends to form two sockets, so that the front socket for the brush wires and the rear socket for the line.

The introduction of a line in the rear socket can currently cannot be carried out with an automated tool and is generally done manually with versus with automatic Tool inserted into the contact and fastened lead increased costs.

The drilling of holes in such a holder requires the

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accurate positioning of the drill for the holes to create a wall of uniform thickness to perform well but thin enough to be crimped or crimped to keep the wires in the holes.

In addition, the drilling itself is inconvenient because it is manufacturing expensive and requires additional machine tool capacity, machine workers and the conveyance of parts. In the case of the above The contact described in the cited patent is further contemplated to have each holder individually and separately during manufacture and assembly is dealt with. This own treatment is time consuming and expensive. In addition, this contact also requires that the sockets are electroplated in an electroplating bath in order to improve their electrical properties. This electroplating or peeling is a separate operation and is conditional on some Applications that vent or exhaust holes are drilled transversely into the socket to allow the plating bath to come out of the socket can be removed.

The invention avoids these limitations and disadvantageous features of the earlier prior art by providing an electrical contact as the connection of an electrical line in an electrical connector, characterized in that it comprises a number of <xial aligned wires, each of which on its front End face is formed at an acute angle that a stamped and formed electrically conductive holder with a back part, a middle part and a front

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Sleeve is provided, further in that the rear part is the electrical Electrically wired line receives that the middle part electrically coupling the rear part and the front parts together, as well as in that the front sleeve & the rear ends of a Number of axially aligned wires, further in that the front sleeve has a seam extending along its length and finally in that means retain the axially aligned wires in the front sleeve to prevent the accidental Prevent loss of wires from the joint.

The invention is explained in more detail below. All in the description Features and measures contained therein can be essential to the invention. The drawings show:

Fig. 1 is a front view of an elek according to the invention

tric contact holder after punching into a flat shape;

Fig. 2 shows the manufacturing and assembly processes for training

Extension of the holder to an electrical contact from the flat piece of FIG. 1;

FIG. 3 is a cross-section "of the contact holder of FIG

along the line III-III in the direction of the arrow;

FIG. 4 shows a cross section of the contact holder of FIG

along the line IV-IV in the direction of the arrow;

FIG. 5 shows a cross section of the contact holder of FIG

along the line V-V in the direction of the arrow;

6 shows a cross section of the contact holder of FIG.

along the line VI-VI in the direction of the arrow; 7 shows a cross section of the contact holder of FIG.

along the line VII-VII in the direction of the arrow; FIG. 8 shows a cross section of the contact holder of FIG.

along the line VIII-VIII in the direction of the arrow; 9 is a view of a completed electrical

Contact before connecting a line; Fig. 1o another embodiment of the punched

Holder of Fig. 1;

Figure 11 is a partial front view of the finish

th holder of the other embodiment of the

Fig. 1o.

Fig. 1 shows a view of a brush contact holder 1oo, the was punched out of flat material before forming into a three-dimensional holder. The punched holder 1oo includes a front part 11o, which leads to a front bushing for axial aligned brush contact wires is designed.

The front part 11o is connected via a narrowed part 12o with a second part 13o, which acts as a socket for receiving a electrical line is used. A part 14o of the holder is designed to stretch the line insulation. A connector 15o ensures the attachment of the holder 1oo to a carrier strip, not shown.

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The front part 11o has sides 112, 114. The rear part 13o includes pages 132,134. The isolation clamping part 14o has the Triangle parts 142,144.

Fig. 2 shows the manufacturing processes of the brush contact from a thin flat piece of an electrically conductive material. A single flat or level holder is made from a strip (e.g. a flat strip of material), whereupon it gradually receives the desired three-dimensional shape when it is through the die or die stations are transported. The flat blank strip used is preferably an alloy based on copper that is pre-electroplated with a material such as tin that either resists oxides or salts or is soft creates crumbly oxides. Tinning is relatively inexpensive and gives performances that are acceptable for most applications are. Gold plating can be used where better results are required. Another acceptable material is a Blank with an inlaid strip or a lining with a similar conductive material on one or more important points (i.e. the front or rear socket or part of it). The plated or lined or the inserted part is placed on the side of the flat blank, which then becomes the inner part when the contact is rolled up.

The holders 1oo are in different stages of completion a support strip 16o mounted, which has guide holes 162,

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thus the carrier strip 160 and the holder I00 from one station can be conveyed to the other in the punch press.

In the punch press position A, which corresponds to the first punch press station, the holder I00 is punched out as a flat piece, which comprises the holder parts 11o, 12o, 13o, 14o. The holder I00 is through a carrier bar connector 15o to the carrier bar 160 connected. In this operation the holder is flat (i.e. essentially two-dimensional).

In the position B corresponding to the second punching station In the punch press, the punch has the three parts 11o, 13o, 14o upwards and formed outwardly from the plane (or from the second dimension) in which the holder I00 in the punch press position A. was. The sides 112,114 of the front portion ΙΙ0 of the holder extend now approximately at an angle of 90 ° upwards from the plane in which the holder is punched during this operation. the three parts 11o, 13o, 14o now formed are in this operation generally cupped.

In the punch press position C, the sides 112, 114 of the front part ΙΙ0 of the holder continued to be bent or rolled by the punch press, with the sides 112, 114 facing each other, but not completely together. Parts 13o, 14o become in this position compared to the position in the punch press position B no longer significantly deformed.

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In the press position D, the outer edges of the sides 112, 114 of the front part are juxtaposed, almost against one another butting positions to form a socket or bottomless socket. The edges of the sides 112, 114 meet an open hem 113 that extends the length of the front part the sleeve extends, the open seam 113 gives a small gap for easier insertion of the brush wires, although it is not absolutely necessary in some applications.

In the punching or die position E, a number of thin, straight, generally axially aligned wires 2oo, each provided with acute-angled front end surfaces 21o, introduced into the front socket or sleeve 11o, which is equipped with beads 115 to hold the wires 2oo in it and to to back up. The beads 115 extend radially around the front part 11o of the holder and transversely to the seam 113, which is now because of the sikkens is closed (the sides 112,114 are now against each other).

In the punch press at station E there is a pin, not shown inserted into the rear part of the front socket 11o to a to form rear stop for the wires inserted from the front. Then the beads 115 secure the wires 2oo in the socket, and the pen can be removed.

The wires 2oo are preferably joined together at their rear ends attached to form an integral bundle. This method of tying the wires into a bundle is described in the US patent application

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application 863 366.

In the position F, the front part 11o has a further bead 116 secured to form an additional holder for the wires 2oo in the front part of the socket 11o.

In the position G, the front end of the part 11o has a further bead 117, which the front end of the holder on the approximate Dimension of the bundle of axially aligned wires 2oo when these are tightly bundled. The keeper will "Dimensioned" to ensure a closer fit of the wires 2oo and the individual wires 2oo better to each other and to the Align the axis of the bushing.

In the punch press position G, an insulated wire can also be arranged in the rear part 13o of the holder 1oo. At the front Part of the wire 3oo has the insulation removed to expose the line 31o. This generally extends over the rear part 13o, which is shell-shaped in this manufacturing process and the rear bushing acts at the end of the shaping process. The line or wire 3oo has insulation 32o in the part that is in the part with insulation 14o.

The wire 3oo is preferably inserted into the through pages 132,134 Formed shell introduced by being arranged over the shell longitudinally axially to her, whereupon he down into the shell is introduced. This introduction of the wire is therefore advantageous

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because it can be carried out with an automatic device. Also, the shell directs the wire down into a proper one Location.

Usually, the insulated wire 300 is inserted into the shell 13o and fastened there by the user after the front part of the contact from the factory completely finished and assembled is. Thus, the explanation for the use of the line 3oo is only for the sake of clarity and completeness for understanding given the environment of the invention.

If the wire 3oo is to be inserted by hand, the rear Socket 13a can be fully formed prior to insertion. The axis of the wire 3oo would then be aligned with the axis of the socket cursing. The wire is then introduced in progressive motion on the common axis.

In the punch press position H, sides 132, 134 of part 13o and parts 142, 144 are formed over and around wire 3oo. The sides 132,134 of the part 13o (now sunk over the line) offer an electrical and mechanical connection with of the stripped wire 31o. The parts 142,144 hold the isolated Line 3qo, when crimped around the wire, grip insulation 32o and provide mechanical Strain relief to protect the electrical coupling of the sides 132, 134 with the stripped conductor 31ο.

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Fig. 3 shows a cross section of the holder part 11o in the punch press position B. In this operation, pages are 112,114 of the holder part 11ο bent upwards and extend their outer edges approximately perpendicular to the carrier strip, not shown, and the original flat punched piece. The cross section of the Halters is now O-shaped.

Figure 4 is a cross section of the holder portion 11o in the punch press position C. In this operation, the outer edges of the sides 112, 114 of the holder part Ho are facing inwards as a partial circle bent. The cross-section of the holder now has a C-shape.

Fig. 5 shows a cross section of the holder in the punch press position D. In this operation, the outer edges of the sides 112, 114 are almost completely bent together at the open seam 113. The cross section the holder is now essentially U-shaped with a narrow gap at the open seam 113.

Fig. 6 shows a cross section of the holder in the punch press position F. In this operation, a number of wires 2oo are relatively loose in the holder part 11o through the sides 112, 114 held.

Figure 7 is a cross-section of the holder in the punch press position G. In this operation, the wires 2oo in the socket 11o by sizing the socket to the circumference of the wires tighter

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as held in FIG. 6.

Fig. 8 shows a cross section of the rear socket holder 13o in the punch press position H. The line 3oo is in the rear socket 13o by a B-shaped pinching of the sides 132,134 held. This type of pinch or bead, commonly known, looks like the letter B in cross section.

Fig. 9 gives a perspective view of one according to the invention electrical contact before attaching an electrical line. The contact includes the front holder portion or socket 11o with the axially aligned wires 2oo, each of which is provided with acute angled end surfaces 21o, extending from the front end of the holder protrude. A number of beads 115,116,117 secure the wires in the front socket 11o. The middle narrowed part 12o connects the front socket 11o to the rear shell 13o, which is empty and not shaped into a socket. The isolation gripping and clamping parts 142, 144 are also shown.

The contact 100 shown in FIG. 9 is separated from the carrier strip and also the connection piece to the carrier strip is cut off from the contact. Usually the contact is not made by the bar and the connector to the carrier bar separated until the electrical line is attached, if it is mechanical to be coupled with the contact. The connection piece of the contacts with the carrier bar also provides an easy way to edit a number of contacts at the same time. The same-

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moderate alignment of the contacts with respect to the carrier strip as well as the even distance between two consecutive contacts on the carrier strip facilitates mechanical or automatic processing.

Fig. 1o shows another embodiment or another Shaping of the punched holder of FIG. 1. There is a punched holder 4oo in planar, essentially two-dimensional Shape shown. The parts 12o, 13o, 14o, 15o can with the corresponding Parts of Fig. 1 be identical. An enlarged front part 41o, which is designed to form the enlarged front part 41o becomes, after its three-dimensional shape to the wire-receiving socket and comprises the parts 411,412,413,414,415,416. The middle parts 412, 415 are opposite the corresponding front parts 411,414 and the rear parts 413,416 laterally offset. To The shaping of the front socket is the seam of the converging Pages staggered.

FIG. 11 shows a front view of the holder of FIG. 1o formed into a three-dimensional piece. The partially shown Brush wires 2oo protrude from the front socket 41 ο. The parts 411,412,413 meet with the corresponding parts 414,415, 416 together at a hem 417, which is offset to the side Has middle part. The laterally offset seam 417, in contrast to the straight seam 113 of the exemplary embodiment in FIG. 2-9 an additional security that no wire can slip through the hem. For many applications, the beads or are sufficient

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Crushing the front part alone to keep the wires secure in the holder to clamp. As a further method for producing the contact according to the invention, a number of individual thin axially aligned contact wires can be used in place of the welded bundle. In this case, the seam 113 (see p. Punch press position D in Fig. 2) will likely be closed (or substantially closed) to get the individual wires in to keep the socket. The many fine, axially aligned wires in this alternate embodiment are preferred individual strands threaded into the front socket 11o in a funnel shape the rear part of the front socket contains appropriate devices to attach the wires to the desired Stop depth.

To protect the wires, a sleeve can also be placed over the contact brush wires to be pulled. This sleeve would extend beyond the axially aligned wires.

In addition to the exemplary embodiments described above, there are still others are possible without departing from the scope of the invention. E.g. the sides of the hem could overlap or the hem can be worn out (both are also possible). The wires can be fastened in the holder in another way, e.g. soldered in the socket in addition to or instead of the disclosed beading. Other rear parts of the holder are also possible, such as solderless winding connections or connections for printed circuits that an advantage for certain applications to accommodate a cable

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could be. In some cases the back of the contact can be a solder tail and does not need an enlarged back another formation. The sequence of the punching presses can also be changed in order to meet the requirements of production, with a work step can be expanded into several work steps and vice versa, that several work steps are combined into one can. In some cases, the press can also be idle be beneficial.

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Read 11 e

Claims (11)

Claims Electrical contact for use as a connection to an electrical Cable in an electrical connector, characterized in that it comprises the following components: a number of axially aligned wires (2oo), each provided with an acute-angled front surface (21o), a punched out and molded electrically conductive holder housing (1oo) having a rear portion (13o), a central portion (12o) and a front socket (11o), then in that the rear part (13o) receives the electrical line (3oo) in an electrically connected manner, further in that the middle part (12o) electrically couples the rear part (13o) and the front part (11o) together and that the front bushing (11o) has the rear ends of a number of axially aligned wires (2oo), further by the fact that the front bushing (11o) with a extends over their Length extending hem (113) is provided, and finally in that a device (117) the axially aligned Wires (2oo) in the front sleeve (11o) secures to the 909849/0848 -2- 2922057 accidental loss of wires (2oo) from socket (11o) too impede. 2. Electrical contact according to claim 1, characterized in that the seam (417) has a laterally offset part (412, 415)
comprises on the length of the front bushing (41o). 3. Electrical contact according to one of the preceding claims, characterized in that the seam (113) by the one on top of the other meet two adjacent sides (112,114) formed will. 4. Electrical contact according to one of the preceding claims, characterized in that the seam (113) is a non-welded one Hem is. 5. Electrical contact according to one of the preceding claims, characterized in that the axially aligned wires
(2oo) are attached to each other at their ends (115). 6. Electrical contact according to one of the preceding claims, characterized in that the device securing the wires (2oo) in the front socket (11o) has a number of
represents radially inwardly directed beads (115) of the front sleeve (11o) and in that these beads (115) are arranged at axially protruding points along the front bushing (11o). 909849/0848 7. Electrical contact according to one of the preceding claims, characterized in that the contact holder housing (1oo) comprises a base layer of an electrically conductive material intermeshing with a different material on at least one selected one inner part of the front socket (11o) is related, further in that the other material is an electrically conductive Material is which is resistant to oxides and salts in order to have a low value between the holder (1oo) and the wires (2oo) To offer ohmic resistance when the wires (2oo) are fastened (115) in the holder (1oo). 8. Electrical contact according to claim 7 , characterized in that the base material is an alloy containing copper and the other material is tin. 9. A method for producing an electrical contact according to claim 1, for an electrical connector with the following Operations: Manufacture of a contact housing with a Front part that is used to accommodate a number of fine, axially aligned wires protruding from either is sleeve-shaped or sock-shaped, and which also has a rear part for receiving an electrical line, furthermore inserting a number of wires into the front part and securing the wires in the front part to close the wires therein secure, characterized in that the manufacturing process of a contact housing comprises the following operations: punching of the contact housing from a flat piece of essentially 909849/0848 union of uniform thickness with enlarged front and rear parts, the corresponding when formed upwards Edges of the front and rear parts forms a front and rear sleeve, as well as molding the corresponding sides of the enlarged front part upwards and wrapped in a position in which the outer edges of the sides meet, to form the front part sleeve or sleeve-shaped, whereby a three-dimensional contact for receiving a number of axially aligned wires is created from a stamped sheet of uniform thickness. 10. The method according to claim 9, characterized in that it is also the additional work step of shaping the rear part in comprises a tray for receiving the conduit. 11. The method according to claim 1o, characterized in that it the further operations of inserting the duct into the rear shell and shaping the sides of the rear Shell includes around and over the line to electrically couple it to the contact. Description - 5 - 9098 49/0848