EP0716474A1 - Contact element for connecting two contact pieces - Google Patents

Abstract

The contact element (100) is used to provide an electric contact between the facing contact surfaces (2, 3) of a pair of heavy current contacts (1, 4) and accommodates variations in the relative spacing of the contact surfaces resulting from mfg. tolerances. The contact element has a V-shaped cross-section, with a number of parallel transverse contact ridges (105) spaced along its longitudinal axis (110), with one of the contact surface contacted at the ends of the V arm, the other contact surface contacted at the apex of the V.

Description

TECHNICAL AREA

The present invention relates to the field of electrical contacts. It relates to a contact element for the electrical connection of two contact pieces which lie opposite one another with contact surfaces, which contact element extends along a longitudinal axis and comprises a plurality of contact webs which are arranged essentially parallel to one another and transversely to the longitudinal axis and which are connected to one another at their ends in a base area and protrude from the base by a height in the middle.

Such a contact element is e.g. known from EP-A2-0 202 564, wherein the element disclosed there is only suitable, due to the geometry used, for bridging tolerances between the contact pieces which are in the range of tenths of a millimeter.

STATE OF THE ART

In electrical engineering, there are a large number of applications in which two contact surfaces, which can be flat or curved and are spaced apart, are brought into contact with one another by the use of spring-formed contact elements. High currents often have to be transmitted via such electrical contacts.

The distance between the contact surfaces of two contact pieces, in particular of high-current contacts of electrical distribution or switching systems and other electrical devices, can vary greatly due to manufacturing tolerances and / or existing shape and position deviations. An ideal electrical contact element must therefore take up minimal space, i.e. lowest loss of conductive cross-section of the contact pieces and smallest installation width of the contact element, the largest possible tolerance range, resulting from the above Bridge inaccuracies and shifts.

At the same time, the transmission of the electrical currents that occur in practice is necessary both in normal operation and in the event of a fault (short circuit), taking into account the above. ensure maximum tolerance and position deviations. Inexpensive producibility and simple assembly of the contact element as well as little processing effort on the contact pieces must of course also be guaranteed.

Various contact elements are already known which at least partially and with different weightings meet the above requirements. A number of these known contact elements are based on spring elements produced by stamping. For example, a contact element is known from DE-OS-1 665 132, which has two parallel, straight edge strips, between which contact webs separated by slots run. The two edges of the contact webs are each formed in the region of the central section as a mirror image of one another in an arc shape. The contact webs are twisted about their longitudinal axis out of the element plane, so that the arcuate edges provide contact with the adjacent contact surfaces of the contact pieces. The maximum distance that can be bridged (the tolerance bridging) between the contact surfaces depends largely on the width of the contact webs. By unit of length of the contact element to accommodate a sufficient number of contact webs for the current transmission, the width of the contact webs is limited overall for a predetermined width of the contact element, which leads to a corresponding limitation of the resulting tolerance bridging.

By enlarging the grid, i.e. Increasing the distance from the center of the contact web to the center of the contact web, the width of the contact web and thus the tolerance bridging can be increased. However, this is accompanied by a reduction in the number of contact webs per unit length and presupposes a widening of the contact element itself. However, an increase in the number of contact webs per unit length while maintaining the tolerance bridging is possible if, according to DE-OS-2 243 034, the edge strips are gathered in waves, so that the contact webs partially overlap. However, the production of such contact elements is complex. In addition, the gathered edge strips can represent mechanical weak points.

Another known constructive solution is described in EP-A1-0 520 950. The interlocking of the upper and lower boundary lines of a contact web in the area of the middle section allows the effective contact web width to be enlarged and thus a greater tolerance bridging with a reduced grid dimension and moderate contact element width.

Taking into account the two main requirements, namely the minimal installation space and sufficient power transmission, all of the above proposed solutions are unable to ensure the large tolerance bridging in the millimeter range desired in practice. They therefore require a precise preparation or reworking of the contact pieces. Furthermore, for the installation of all of the above-mentioned contact elements produced by stamping technology, production technology is required recesses which are expensive to produce are necessary (see, for example, FIGS. 1 and 2 in DE-OS-1 665 132 or FIGS. 1 and 2 of EP-A1-0 520 290) or, in the case of larger dimensions, additional elements are provided for fixing the contact element in the recess .

Further technical solutions are based on electrical contact elements made from wire in the form of coil springs. For example, GB-PS-1 542 102 describes such a contact element for use in round or flat-shaped contact pieces. In DD-A1-244 438, position stabilizers are additionally proposed for these contact elements. In the publications EP-A1-0 314 229 and EP-A1-0 573 690, contact elements in the form of wire spirals are disclosed for cylindrical contact pieces. The advantages of this group of contact elements are the large tolerance bridging with a sufficiently large number of contact webs per unit length.

The main requirement, namely a large tolerance bridging with sufficient current transferability, can be ensured by the contact elements based on the principle of the coil spring. However, the large loss in conductive cross section of the contact pieces associated with these proposed solutions must be taken into account. An essential prerequisite for the use of these contact elements is therefore the presence of a sufficiently large installation space that compensates for the narrowing of the cross-section, which resembles a bottle neck. This requires a significant increase in the dimensions of the contact pieces compared to the conductive cross section required for current transmission, which is not readily possible for one of the intended areas of use of the contact element, namely in switchgear systems, due to insulation-technical boundary conditions.

Finally, a contact element is known from EP-A2-0 202 564 mentioned at the outset (see in particular the FIGS. 1, 6 and 6 there) in which the parallel contact webs are not twisted about their longitudinal axis, but are bent out of the base surface in an arc shape. One contact surface is contacted by the curved middle regions of the contact webs, the other contact surface by the web bridges which connect the ends of the contact webs to one another. Because of the uniform curvature, the contact webs of these known contact elements are deformed under pressure, which on the one hand does not allow sufficient spring travel and on the other hand does not define any clear contact points in the central region of the webs.

PRESENTATION OF THE INVENTION

It is therefore an object of the invention to provide a contact element for the transmission of high electrical currents, which allows the greatest possible tolerance range to be bridged between the contact pieces to be connected with a small space requirement and a small installation width.

The object is achieved in a contact element of the type mentioned in that the contact webs are bent substantially V-shaped, each of the contact webs being divided into two straight legs of essentially the same length, which form a bending angle of less than 180 ° with one another, and wherein the electrical contact is made to the one contact surface in the bending region of the contact webs. The V-shaped bend creates a clearly defined contact point. The straight legs form spring elements which can be clearly optimized with regard to the spring properties and in particular the spring travel and the current transferability.

A first preferred embodiment of the contact element according to the invention is characterized in that the contact webs are designed as sheet metal strips, and that the contact webs have a maximum web width in the bending region, and that the legs each have a taper that increases towards their center, the minimum web width of which is smaller than the maximum web width. Through the appropriate choice of the ratio of the leg length to the minimum web width and the thickness of the sheet metal strips, the spring range and the current transferability can be varied within a wide range, as well as easily adapted to specific application requirements.

A second embodiment of the invention is characterized in that an arching oriented in the opposite direction to the bending is molded into the contact webs in the bending area, and that the contact webs have a further tapering in the area of the arching. As a result, the number of contact points can be expanded in a defined manner without the spring properties of the contact element changing significantly.

In a further preferred embodiment, edge beads running parallel to the longitudinal axis are formed in the connection areas of the contact webs, which are preferably oriented opposite to the V-shaped bend of the contact webs. This ensures that for finally long contact elements that are not connected at their ends, there is an installation in straight recesses without additional fastening elements. In addition, simple line contacts that exist at least in sections along the longitudinal axis of a contact element are formed.

A further preferred embodiment is characterized in that the contact webs in pairs on alternating sides by means of individual ones running parallel to the longitudinal axis Bridge bridges are interconnected. The mutual connection or the mutual free cuts between the contact webs give the contact element a spring characteristic in the direction of its longitudinal axis. This spring property can be exploited to create a self-retaining element for any shape of socket or plug by connecting the end webs (chaining) of a finally long contact element.

A further preferred embodiment is characterized in that the bent contact webs are each inclined out of the base area by an average angle of inclination of less than 90 ° and that the contact webs are connected to one another in pairs on alternate sides by means of individual web joints, either the contact webs and the web joints consist of a wire and the contact element is made of an elongated wire by free-form bending, or each consist of a sheet metal strip, and the contact element is made of a strip-shaped strip material by punching and bending operations.

Such a contact element is simple in construction and easy to manufacture, and can be flexibly adapted to a wide variety of applications in the linked state.

Further embodiments result from the dependent claims.

BRIEF EXPLANATION OF THE FIGURES

Fig. 1

ein erstes Ausführungsbeispiel für ein Kontaktelement nach der Erfindung aus Blechstreifen mit einfacher Kopfkontaktstelle und durchgehenden Stegbrücken in der Seitenansicht in Längsachsenrichtung (a) und in der Draufsicht (b);

Fig. 2

das Kontaktelement nach Fig. 1 in der Seitenansicht quer zur Längsachse;

Fig. 3

ein zweites Ausführungsbeispiel für ein Kontaktelement nach der Erfindung aus Blechstreifen mit zweifacher Kopfkontaktstelle und durchgehenden Stegbrücken in der Seitenansicht in Längsachsenrichtung (a) und in der Draufsicht (b);

Fig. 4

ein drittes Ausführungsbeispiel für ein Kontaktelement nach der Erfindung aus Blechstreifen mit einfacher Kopfkontaktstelle und paarweise wechselnden Stegbrücken in der Seitenansicht in Längsachsenrichtung (a) und in der Draufsicht (b);

Fig. 5

das Kontaktelement nach Fig. 4 in der Seitenansicht quer zur Längsachse;

Fig. 6

ein viertes Ausführungsbeispiel für ein Kontaktelement nach der Erfindung aus Blechstreifen mit doppelter Kopfkontaktstelle und paarweise wechselnden Stegbrücken in der Seitenansicht in Längsachsenrichtung (a) und in der Draufsicht (b);

Fig. 7

ein fünftes Ausführungsbeispiel für ein Kontaktelement nach der Erfindung aus Draht mit einfacher Kopfkontaktstelle in der Seitenansicht in Längsachsenrichtung (a) und in der Draufsicht (b);

Fig. 8

ein sechstes Ausführungsbeispiel für ein Kontaktelement nach der Erfindung aus Draht mit doppelter Kopfkontaktstelle in der Seitenansicht in Längsachsenrichtung (a) und in der Draufsicht (b); und

Fig. 9

das Kontaktelement nach Fig. 8 in der Seitenansicht quer zur Längsachse.

The invention will be explained in more detail below on the basis of exemplary embodiments in connection with the drawing. Show it

Fig. 1

a first embodiment of a contact element according to the invention made of sheet metal strips with a simple head contact point and continuous web bridges in the side view in the longitudinal axis direction (a) and in the top view (b);

Fig. 2

the contact element of Figure 1 in side view transverse to the longitudinal axis.

Fig. 3

a second embodiment of a contact element according to the invention of sheet metal strips with double head contact point and continuous web bridges in the side view in the longitudinal axis direction (a) and in the top view (b);

Fig. 4

a third embodiment of a contact element according to the invention made of sheet metal strips with a simple head contact point and bridge bridges changing in pairs in the side view in the longitudinal axis direction (a) and in the top view (b);

Fig. 5

the contact element of Figure 4 in side view transverse to the longitudinal axis.

Fig. 6

a fourth embodiment of a contact element according to the invention made of sheet metal strips with a double head contact point and pairs of bridge bridges in the side view in the longitudinal axis direction (a) and in plan view (b);

Fig. 7

a fifth embodiment of a contact element according to the invention made of wire with a simple head contact point in the side view in the longitudinal axis direction (a) and in the top view (b);

Fig. 8

a sixth embodiment of a contact element according to the invention made of wire with a double head contact point in the side view in the longitudinal axis direction (a) and in the top view (b); and

Fig. 9

8 in the side view transverse to the longitudinal axis.

WAYS OF CARRYING OUT THE INVENTION

The exemplary embodiments of the contact element according to the invention described in more detail below can be divided into three basic forms A1, A2 and A3. The basic shapes A1 (Fig. 1-3) and A2 (Fig. 4-6) can be produced from a sheet metal strip by simple stamping and bending operations, the basic shape A3 (Fig. 7-9) from a wire by inexpensive free-form bending. The large spring area with the smallest possible installation space of the contact element in the basic shapes A1 and A2 results from the optimized geometric dimensions of the contact webs, that of the contact element in the basic shape A3 from the optimized torsional bending joints, which result from the simultaneous inclination of the contact webs relative to the base area.

Due to the optimized grid dimension in relation to the contact element width, the contact element in the basic forms A1 to A3 is particularly suitable for use as a high-current contact. The contact element in the basic form A1 has open ends. Due to the edge beads (web bridges) embossed on both sides, which form the foot contact points, it is also suitable for large beech and plug diameters without additional Holding elements can be used in cost-saving straight recesses (ie without dovetail guide).

In the chained form, i.e. by connecting the two ends to form a ring-shaped closed element, the contact element of the basic forms A2 and A3 can be rotated in itself and can be used in sockets and on plugs without time-consuming rolling or reworking. Likewise, the linked state of the contact element in the basic forms A2 and A3 makes it possible to produce time-saving and cost-saving straight recesses in the contact pieces. Furthermore, because of the spring properties in the longitudinal axis direction, the additional holding elements for fixing, which are otherwise customary in the case of large socket and plug diameters, can be omitted in the interlinked elements. Likewise, the elasticity in the longitudinal direction allows use over a varying diameter range for sockets and plugs.

1 to 3 show two exemplary embodiments of the above basic form A1. 1 shows a contact element 100 which is produced in a follow-up cutting tool by punching and bending operations from a strip-shaped strip material. The contact element 100, which extends along a longitudinal axis 110, comprises a multiplicity of contact webs 105 of web thickness c arranged parallel to one another and transversely to the longitudinal axis 110 in a grid dimension f, each of which at their two ends via a continuous web bridge 104 or 106 with the web bridge width k (Fig. 1 (b)) are connected. The contact webs 105 are bent in a V-shape with a radius R3 (FIG. 1 (a)). Each contact web 105 is thereby divided into two straight legs 107 and 112 of equal length, which run between the bending area and the respective web bridge 106 and 104, respectively. Because of the bend, the two legs 107, 112 form a bend angle α with one another that is less than 180 °. The bending area protrudes vertically from the base 6 that with a contact element width i, the contact element 100 has a contact element height j that can be used to bridge the tolerance.

When the contact element 100 is inserted between the opposing contact surfaces 2, 3 of two contact pieces 1, 4 in a corresponding recess 5 (FIG. 1 (a)), the bending area forms a head contact point 101 with a linear contact area 113 (FIG. 2) with one Contact area 2, while the bridge bridges 104, 106 form foot contact points 102, 103 with line-shaped contact areas 114 (FIG. 2) with the other contact area 3 (in recess 5). In the area of the bridge bridges 104, 106, edge beads 115, 116 with the radius R2 and the base height h are embossed or molded in the direction of the longitudinal axis 110.

The contact webs 105 have a maximum web width e in the bending area. With a leg length b, the legs 107, 112 each have a taper 109, 111 increasing towards their center, the minimum web width a of which is smaller than the maximum web width e. In the bending region of the contact webs 105, embossments 108 with the radius R4 (FIG. 2) extending in the web direction are additionally introduced. These enable the use of the contact element 100 at any angle to the longitudinal axis 110 of the contact element and reduce the formation of ribs when used perpendicular to it.

• die Kontaktstege 105 des Kontaktelementes 100 basieren auf dem Blattfederprinzip und arbeiten damit als ideale Biegefeder;
• der grosse Federweg (Millimeterbereich) der Kontaktstege 105 resultiert aus der gezielten Verjüngung 109, 111 der beidseitigen Schenkel 107, 112, welche Verjüngung durch die minimale Stegbreite a, die Schenkellänge b und den Radius R1 der Verjüngung (Fig. 1(b)) beschrieben werden kann;
• durch die geeignete Wahl des Verhältnisses der Schenkellänge zur minimalen Stegbreite, b/a, und der Stegdicke c kann der Federbereich und die Stromübertragbarkeit in weitem Rahmen variiert werden;
• jeder Kontaktsteg 105 besitzt zwei Fusskontaktstellen 102, 103 und eine Kopfkontaktstelle 101;
• der Radius R2 (Fig. 1(a)) stellt in Verbindung mit den um die Fusshöhe h sickenartig herausgebogenen Fusskontaktstellen 102, 103 jeweils einen linienförmigen Kontaktbereich 114 entlang des gesamten Kontaktelementes sicher, die variable Tiefe und Breite der Randsicken 115, 116 bestimmen dabei die Einsatzmöglichkeiten;
• für die Kopfkontaktstelle 101 ergibt sich infolge des Radius R3 und der maximalen Stegbreite e und der im Biegewinkel α < 180° zueinander gebogenen Schenkel 107, 112 ebenfalls ein linienförmiger Kontaktbereich 114 (Fig. 2);
• das Rastermass f definiert die Zahl der Kontaktstege 105 je Längeneinheit des Kontaktelementes 100; es ist entsprechend den Einflussgrössen maximale Stegbreite e, Schnittbreite g zwischen den Kontaktstegen 105 (Fig. 1(b)) und Stegdicke c kleinstmöglich gewählt;
• die Kontaktelementbreite i und die Kontaktelementhöhe j sind durch Wahl der Schenkellänge b und des Biegewinkels α variabel einstellbar;
• der Radius R4 (Fig. 2), mit dem die Kontaktstege 105 seitlich abgerundet sind, ermöglicht den Einsatz des Kontaktelementes 100 in beliebigen Winkeln zur Längsachse 110 und vermindert die Riefenbildung beim Einsatz senkrecht dazu;
• die Stegbrückenbreite k wird durch die variablen Rundungsradien R5 und R6 und die Einschnitttiefe 1 (Fig. 1(b)) festgelegt.

The properties of the contact element 100 can be summarized as follows:

• the contact webs 105 of the contact element 100 are based on the leaf spring principle and thus work as an ideal spiral spring;
• the large spring travel (millimeter range) of the contact webs 105 results from the targeted tapering 109, 111 of the legs 107, 112 on both sides, which taper can be described by the minimum web width a, the leg length b and the radius R1 of the taper (FIG. 1 (b));
• the spring area and the current transferability can be varied within a wide range by a suitable choice of the ratio of the leg length to the minimum web width, b / a, and the web thickness c;
• each contact web 105 has two foot contact points 102, 103 and a head contact point 101;
• the radius R2 (FIG. 1 (a)) in conjunction with the foot contact points 102, 103 bent out like a bead around the height h ensures a linear contact region 114 along the entire contact element, the variable depth and width of the edge beads 115, 116 determining the Possible uses;
• for the head contact point 101 there is also a linear contact area 114 (FIG. 2) as a result of the radius R3 and the maximum web width e and the legs 107, 112 bent toward one another at the bending angle α <180 °;
• the grid dimension f defines the number of contact webs 105 per unit length of the contact element 100; according to the influencing variables, the maximum web width e, the cutting width g between the contact webs 105 (FIG. 1 (b)) and the web thickness c are chosen to be as small as possible;
• the contact element width i and the contact element height j can be variably adjusted by choosing the leg length b and the bending angle α;
• the radius R4 (FIG. 2) with which the contact webs 105 are rounded on the side enables the use of the contact element 100 at any angle to the longitudinal axis 110 and reduces the formation of grooves when used perpendicularly thereto;
• the bridge bridge width k is determined by the variable rounding radii R5 and R6 and the incision depth 1 (FIG. 1 (b)).

Another embodiment of the basic form A1 (with the same properties mentioned above) is shown in FIG. 3. The contact element 300 there with the longitudinal axis 310 has essentially the same configuration as the contact element 100 from FIG. 1 and comprises contact webs 305 connected by web bridges 304 and 306 with legs 307 and 312 which have tapering 309 and 311 in the central region. Edge beads 315 and 316 are formed in the area of the bridge bridges 304, 306 and form foot contact points 302 and 303, respectively. Likewise, embossments 308 are provided in the bending area.

In contrast to FIG. 1, in the case of the contact element 300 in the bending area of the contact webs 305, an arch 314 oriented opposite to the bend is formed, so that two head contact points 301a and 301b result on the upper contact surface 2. The contact webs 305 have a further taper 313 in the region of the arch 314.

4 to 6 show two exemplary embodiments for the above-mentioned basic form A2. FIG. 4 shows a contact element 400, which is likewise produced from a strip-shaped strip material in a follow-up cutting tool by punching and bending operations. The contact element 400 extending along a longitudinal axis 410 comprises a multiplicity of contact webs 405 of the web thickness arranged parallel to one another and transversely to the longitudinal axis 410 in a grid dimension f c, which at their two ends are not connected to one another continuously, but in pairs on alternating sides by means of individual web bridges 404, 406 (meandering) running parallel to the longitudinal axis 410. The V-shaped contact webs 405 are each divided into two equally long, straight legs 407 and 412 with corresponding tapering 409 and 411.

The contact webs 405 have the same configuration and geometry as the contact webs 105 and 305 of the examples from FIGS. 1 and 3 and show the same spring behavior between the contact pieces 1 and 4 with the same bending angle α and the similar embossments 408 and edge beads 417, 418 also the head contact points 401 with their line-shaped contact areas 413 (FIG. 5) and the foot contact points 402 and 403, but because of the short bridge bridges 404, 406 there are no continuous, but only partially linear contact areas 414 (FIG. 5).

• die Kontaktstege des Kontaktelementes 400 basieren auf dem Blattfederprinzip und arbeiten damit als ideale Biegefeder;
• der grosse Federbereich der Kontaktstege 405 resultiert aus den gezielten Verjüngungen 409, 411 der beidseitigen Schenkel 407, 412, beschrieben durch die minimale Stegbreite a, die Schenkellänge b und den Radius R1;
• durch die geeignete Wahl des Verhältnisses der Schenkellänge zur minimalen Stegbreite, b/a, und der Stegdicke c (Fig. 5) kann der Federbereich und die Stromübertragbarkeit in weitem Rahmen variiert werden;
• jeder Kontaktsteg 405 besitzt zwei Fusskontaktstellen 402 und 403 und eine Kopfkontaktstelle 401;
• der Radius R2 stellt in Verbindung mit der Doppelstegbreite d und der um die Fusshöhe h sickenartig herausgebogenen Fusskontaktstellen 402, 403 jeweils einen abschnittsweise linienförmigen Kontaktbereich 414 sicher:
• für die Kopfkontaktstelle 401 ergibt sich infolge des Radius R3 und der maximalen Stegbreite e und der im Biegewinkel α < 180° zueinander gebogenen Schenkel 407, 412 ebenfalls ein linienförmiger Kontaktbereich 413;
• das Rastermass f definiert die Zahl der Kontaktstege 405 je Längeneinheit; es ist entsprechend den Einflussgrössen maximale Stegbreite e, Schnittbreite g zwischen den Kontaktstegen 405 und Stegdicke c kleinstmöglich gewählt;
• die Kontaktelementbreite i und die Kontaktelementhöhe h sind durch die Schenkellänge b und den Biegewinkel α variabel einstellbar;
• der Abrundungsradius R4 (Fig. 5) an den Seiten der Kontaktstege 405 ermöglicht den Einsatz des Kontaktelementes 400 in beliebigen Winkeln zur Längsachse 410 und vermindert die Riefenbildung beim Einsatz senkrecht dazu;
• die Stegbrückenbreite k wird durch die variablen Rundungsradien R5 und R6 und die Einschnitttiefe 1 festgelegt;
• durch die wechselseitigen Freischnitte 419, 420 (Fig. 4(b)) erhält das Kontaktelement 400 eine Federeigenschaft in Richtung der Längsachse 410;
• die Geometrie der Freischnitte 419, 420 wird bestimmt durch die variablen Grössen Doppelstegbreite d, das Rastermass f und den Rundungsradius R5;
• in der beschriebenen Form ist das Kontaktelement 400 in endlichen Längen herstellbar;
• seine selbsthaltende Eigenschaft im geraden Einstich 5 von beliebig geformten Buchsen oder Steckern erhält das Kontaktelement 400 durch das Trennen einer Stegbrücke 404 bzw. 406 und Verbinden der damit geschaffenen Endstege 415, 416 durch thermische Verbindungsverfahren wie Widerstandspunktschweissen oder Laserstrahlschweissen oder durch mechanisches Verketten.

The properties of the contact element 400 can be summarized as follows:

• the contact webs of the contact element 400 are based on the leaf spring principle and thus work as an ideal spiral spring;
• the large spring area of the contact webs 405 results from the targeted tapering 409, 411 of the legs 407, 412 on both sides, described by the minimum web width a, the leg length b and the radius R1;
• the spring range and the current transferability can be varied within a wide range by a suitable choice of the ratio of the leg length to the minimum web width, b / a, and the web thickness c (FIG. 5);
• each contact web 405 has two foot contact points 402 and 403 and a head contact point 401;
• the radius R2 in connection with the double web width d and the foot contact points 402, 403 bent out like a bead around the foot height h each ensure a contact area 414 which is linear in sections:
• for the head contact point 401 there is also a linear contact area 413 as a result of the radius R3 and the maximum web width e and the legs 407, 412 bent toward one another at the bending angle α <180 °;
• the grid dimension f defines the number of contact webs 405 per unit length; according to the influencing variables, the maximum web width e, the cutting width g between the contact webs 405 and the web thickness c are chosen to be as small as possible;
• the contact element width i and the contact element height h can be variably adjusted by the leg length b and the bending angle α;
• the radius of curvature R4 (FIG. 5) on the sides of the contact webs 405 enables the use of the contact element 400 at any angle to the longitudinal axis 410 and reduces the formation of grooves when used perpendicularly thereto;
• the bridge width k is determined by the variable radius of curvature R5 and R6 and the depth of cut 1;
• the mutual cutouts 419, 420 (FIG. 4 (b)) give the contact element 400 a spring characteristic in the direction of the longitudinal axis 410;
• the geometry of the free cuts 419, 420 is determined by the variable sizes of the double web width d, the grid dimension f and the radius of curvature R5;
• in the form described, the contact element 400 can be produced in finite lengths;
• The contact element 400 obtains its self-retaining property in the straight recess 5 of any shaped sockets or plugs by separating a bridge bridge 404 or 406 and connecting the end webs 415, 416 thus created by thermal connection methods such as resistance spot welding or laser beam welding or by mechanical linking.

Another embodiment of the basic form A2 (with the same properties mentioned above) is shown in FIG. 6. The contact element 600 there with the longitudinal axis 610 has essentially the same configuration as the contact element 400 from FIG. 4 and comprises, by means of web bridges 604 and 606, alternately connected contact webs 605 with legs 607 and 612, which have tapering 609 and 611 in the central region. Edge bridges 617 and 618 are formed in the area of the bridge bridges 604, 606, which form foot contact points 602 and 603, respectively. Embossments 608 are also provided in the bending area.

In contrast to FIG. 4, in the case of the contact element 600 in the bending area of the contact webs 605, an arch 616 oriented opposite to the bend is formed, so that two head contact points 601a and 601b result on the upper contact surface 2. The contact webs 605 have a further taper 613 in the region of the arch 616. Here, too, end webs 614, 615 can be connected to one another in order to obtain a linked contact element.

7 to 9 show two exemplary embodiments for the basic shape A3 of the contact element bent from a wire. FIG. 7 shows a contact element 700 which is produced by free-form bending along a longitudinal axis 711 from a wire 710 with a circular cross section. The contact element 700 comprises a plurality of contact webs 707, which are also bent in a V-shape with a bending angle α <180 ° and are each divided into two (straight) legs 706 and 714 by the bending. The contact webs 707 are connected at their ends in pairs on alternating sides by web joints 708, 713. The bent contact webs 707 are inclined out of the base area 6 by an angle of inclination β (FIG. 9). Their bending areas form a head contact point 701 with a linear contact area 704 (FIG. 7 (b)). The web joints 708, 713 form foot contact points 702, 703 with linear contact areas 709 (FIG. 7 (b)).

• die Kontaktstege 707 des Kontaktelementes 700 bestehen aus einem Biege- und Torsionsbalken;
• der grosse Federbereich der Kontaktstege 707 resultiert aus der Federeigenschaft der Steggelenke 708, 713 und der Schenkel 706, 714, die durch die Drahtdicke bzw. Stegbreite a, den Steggelenkradius R1 und die Schenkellänge b definiert ist;
• durch die geeignete Wahl des Verhältnisses der Schenkellänge zur Drahtdicke, b/a, kann der Federbereich und die Stromübertragbarkeit in weitem Rahmen variiert werden;
• jeder Kontaktsteg 707 besitzt eine Kopfkontaktstelle 701 und zwei Fusskontaktstellen 702, 703;
• der Steggelenkradius R1 stellt in Verbindung mit dem runden Draht 710 mit der Drahtdicke a jeweils einen bogenförmig gekrümmten, linienförmigen Kontaktbereich 709 je Fusskontaktstelle sicher;
• für die Kopfkontaktstelle 701 ergibt sich infolge des Radius R3 sowie der Drahtdicke a und der im Biegewinkel α < 180° zueinander gebogenen Schenkel 706, 714 ebenfalls ein bogenförmig gekrümmter, linienförmiger Kontaktbereich 704;
• das Rastermass f definiert die Zahl der Kontaktstege 707 je Längeneinheit; es ist entsprechend den Einflussgrössen Drahtdicke a und Steggelenkradius R1 kleinstmöglich gewählt;
• die Kontaktelementbreite i und die Kontaktelementhöhe j sind durch die Schenkellänge b und den Biegewinkel α variabel einstellbar;
• der kreisrunde Draht der gebogenen Kontaktstege 707 ermöglicht den Einsatz des Kontaktelementes 700 in beliebigen Winkeln zur Längsachse 711 und vermindert die Riefenbildung beim Einsatz senkrecht dazu;
• die Kontaktstege 707 des Kontaktelementes 700 werden durch die Steggelenke 708, 713 verbunden und liegen parallel hintereinander und sind aus der Horizontalen (Grundfläche 6) um den Neigungswinkel β herausgedreht;
• beim Einfedern tauchen die Kontaktstege 707 ineinander;
• durch die wechselnd angeordneten Steggelenke 708, 713 erhält das Kontaktelement 700 eine Federeigenschaft in Richtung seiner Längsachse 711;
• in der beschriebenen Form ist das Kontaktelement in endlichen Längen herstellbar;
• seine selbsthaltende Eigenschaft im geraden Einstich 5 von beliebig geformten Buchsen oder Steckern erhält das Kontaktelement 700 durch das Trennen eines Schenkels und Verbinden der damit geschaffenen Endstege 705, 712 durch thermische Verbindungsverfahren wie Widerstandspunkt- oder Laserstrahlschweissen, oder durch mechanisches Verketten.

The properties of the contact element 700 can be summarized as follows:

• the contact webs 707 of the contact element 700 consist of a bending and torsion bar;
• the large spring area of the contact webs 707 results from the spring property of the web joints 708, 713 and the legs 706, 714, which is defined by the wire thickness or web width a, the web joint radius R1 and the leg length b;
• the spring range and the current transferability can be varied within a wide range by a suitable choice of the ratio of the leg length to the wire thickness, b / a;
• each contact web 707 has a head contact point 701 and two foot contact points 702, 703;
• the web joint radius R1, in conjunction with the round wire 710 with the wire thickness a, ensures an arcuate, linear contact area 709 per foot contact point;
• for the head contact point 701, the radius R3 and the wire thickness a and the legs 706, 714 bent at a bending angle α <180 ° to one another likewise result in an arcuate, linear contact region 704;
• the grid dimension f defines the number of contact webs 707 per unit length; it is chosen to be as small as possible in accordance with the influencing variables wire thickness a and bar joint radius R1;
• the contact element width i and the contact element height j are variably adjustable by means of the leg length b and the bending angle α;
• the circular wire of the bent contact webs 707 enables the use of the contact element 700 at any angle to the longitudinal axis 711 and reduces the formation of grooves when used perpendicularly thereto;
• the contact webs 707 of the contact element 700 are connected by the web joints 708, 713 and lie parallel one behind the other and are rotated out of the horizontal (base area 6) by the angle of inclination β;
• when deflected, the contact webs 707 dive into one another;
• the alternatingly arranged bar joints 708, 713 give the contact element 700 a spring characteristic in the direction of its longitudinal axis 711;
• in the form described, the contact element can be produced in finite lengths;
• The contact element 700 obtains its self-retaining property in the straight recess 5 from any shaped sockets or plugs by separating one leg and connecting the end webs 705, 712 thus created by thermal connection methods such as resistance point or laser beam welding, or by mechanical linking.

A further exemplary embodiment of the basic form A3 (with the same properties mentioned above) is shown in FIG. 8. The contact element 800 made of wire 810 with the longitudinal axis 811 there has essentially the same configuration as the contact element 700 from FIG. 7 and comprises, by means of web joints 808 and 813, contact webs 807 with legs 806 and 814 which are alternately connected in pairs, the foot contact points 802 and 803 with linear contact areas Form 809.

In contrast to FIG. 7, in the case of the contact element 800 in the bending area of the contact webs 807, a bulge 815 oriented in the opposite direction to the bend is formed, so that two head contact points 801a and 801b with corresponding linear contact areas 804 result on the upper contact surface 2. Here, too, end webs 805, 812 can be connected to one another in order to obtain a linked contact element.

It should be pointed out that instead of free-form bending from a circular wire (710, 810), a contact element of the basic shape A3 can also be produced in a follow-up cutting tool by means of punching and bending operations from strip-shaped strip material. Instead of the wire thickness a, the web width a is then included in the dimensioning. The stamped contact webs can then have a radius R4 according to FIG. 9 be provided to enable the use of the contact element at any angle to the longitudinal axis of the contact element and to reduce the formation of grooves when used perpendicular to it.

a =

0,8

c =

0,3

d =

2,55

e =

1,2

f =

1,5

i =

12,7

j =

2,2-3,2

k =

0,8

Overall, the invention results in a contact element which enables maximum tolerance bridging with the minimum installation space required, is simple to manufacture and is suitable for use with high currents. A hardened copper-beryllium alloy, for example, can be used as the material. Exemplary values for a contact element according to FIG. 5 are (in mm):

a =

0.8

c =

0.3

d =

2.55

e =

1.2

f =

1.5

i =

12.7

j =

2.2-3.2

k =

0.8

LIST OF DESIGNATIONS

1.4

Contact piece

2.3

Contact area

5

puncture

6

Floor space

100,300

Contact element

101.301a, b

Head contact point

102,103,302,303

Foot contact point

104,106,304,306

Jetty bridge

105,305

Contact bridge

107,112,307,312

leg

108,308

Embossing

109,111,309,311

rejuvenation

113.114

Contact area (linear)

115,116,315,316

Edge bead

313

rejuvenation

314

Arching

400,600

Contact element

401.601a, b

Head contact point

402,403,602,603

Foot contact point

404,406,604,606

Jetty bridge

405.605

Contact bridge

407,412,607,612

leg

408.608

Embossing

409,411,609,611

rejuvenation

410.610

Longitudinal axis

413.414

Contact area (linear)

415,416,614,615

Final footbridge

417,418,617,618

Edge bead

419,420,619,620

Free cut

616

Arching

700,800

Contact element

701.801a, b

Head contact point

702,703,802,803

Foot contact point

704,709,804,809

Contact area (linear)

705,712,805,812

Final footbridge

706,714,806,814

leg

707,807

Contact bridge

708,713,808,813

Bridge joint

710.810

wire

711.811

Longitudinal axis

815

Arching

a

minimal web width (wire thickness)

b

Leg length

c

Web thickness

d

Double bridge width

e

maximum web width

f

Pitch

G

Cutting width

H

Foot height

i

Contact element width

j

Contact element height

k

Bridge width

l

Depth of incision

α

Bending angle

β

Angle of inclination

Claims (14)

Contact element (100, 300, 400, 600, 700, 800) for the electrical connection of two contact pieces (1, 4), which face each other with contact surfaces (2, 3), which contact element (100, 300, 400, 600, 700, 800 ) extends along a longitudinal axis (110, 310, 410, 610, 711, 811) and a plurality of contact webs (105, 305. arranged essentially parallel to one another and transversely to the longitudinal axis (110, 310, 410, 610, 711, 811) , 405, 605, 707, 807), which contact webs (105, 305, 405, 605, 707, 807) are connected to one another at their ends in a base area (6) and in the middle by a height (j) from the Protruding base area (6), characterized in that the contact webs (105, 305, 405, 605, 707, 807) are essentially V-shaped, each of the contact webs (105, 305, 405, 605, 707, 807) is divided into two straight legs (107, 112, 307, 312, 407, 412, 607, 612, 706, 714, 806, 814) which are of essentially the same length and which have a small bending angle (α) ner 180 ° with each other, and wherein the electrical contact to the one contact surface (2) in the bending area of the contact webs (105, 305, 405, 605, 707, 807) is made. Contact element according to claim 1, characterized in that the contact webs (105, 305, 405, 605) are designed as sheet metal strips (Fig. 1-6). Contact element according to claim 2, characterized in that the contact webs (105, 305, 405, 605) have a maximum web width (e) in the bending area, and that the legs (107, 112, 307, 312, 407, 412, 607, 612 ) each have a taper (109, 111, 309, 311, 409, 411, 609, 611) that increases towards the center, the minimum web width (a) of which is smaller than the maximum web width (e). Contact element according to Claim 3, characterized in that an arch (314, 616) oriented in the opposite direction to the bend is formed in the contact webs (305, 605) in the bending region, and in that the contact webs (305, 605) in the region of the arch (314, 616 ) have a further taper (313, 613) (Fig. 3, 6). Contact element according to one of claims 2 to 4, characterized in that in the connecting areas of the contact webs (105, 305, 405, 605) parallel beads (115, 116, 315, 316) running parallel to the longitudinal axis (110, 310, 410, 610), 417, 418, 617, 618) are molded. Contact element according to claim 5, characterized in that the edge beads (115, 116, 315, 316, 417, 418, 617, 618) are oriented in opposite directions for the V-shaped bending of the contact webs (105, 305, 405, 605). Contact element according to one of claims 2 to 6, characterized in that all contact webs (105, 305) are connected to one another at their ends by means of continuous web bridges (104, 106, 304, 306) running parallel to the longitudinal axis (110, 310) (Fig . 1-3). Contact element according to one of claims 2 to 6, characterized in that the contact webs (405, 605) are connected in pairs on alternating sides by means of individual web bridges (404, 406, 604, 606) running parallel to the longitudinal axis (410, 610) ( Fig. 4-6). Contact element according to one of claims 2 to 8, characterized in that in the bending area of the contact webs (105, 305, 405, 605) for use at any angle to the longitudinal axis and to reduce embossments (108, 308, 408, 608; radius) R4) are introduced. Contact element according to Claim 1, characterized in that the bent contact webs (707, 807) are each inclined out of the base area (6) by an average angle of inclination (β) of less than 90 °. Contact element according to claim 10, characterized in that the contact webs (707, 807) are connected to one another in pairs on alternating sides by means of individual web joints (708, 713, 808, 813). Contact element according to one of claims 10 and 11, characterized in that an arch (815) oriented in the opposite direction to the bend is formed in the contact webs (807) in the bending region (FIG. 8). Contact element according to claim 11, characterized in that the contact webs (707, 807) and the web joints (708, 713, 808, 813) consist of a wire (710, 810) (Fig. 7-9), and that the contact element ( 700, 800) is made from an elongated wire (710, 810) by free-form bending. Contact element according to one of claims 10-12, characterized in that the contact webs (707, 807) each consist of a sheet metal strip, and that the contact element (700, 800) is made from a strip-shaped strip material by punching and bending operations.

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