EP0849120B1 - Electric connector for vehicles - Google Patents

Description

The invention relates to an electrical connector according to the preamble of claim 1, and to a method for producing an electrical connection according to the preamble of claim 15.

Electrical connectors are becoming more and more widely used, particularly in the automotive sector, to make electrical connections between the various functional units. With increasing spread of the electronics in the motor vehicle, the demand for reliable electrical connection paths increases in order to permanently and securely connect the various modules together. However, in the harsh operating environment, various disturbing influences occur, such as, for example, high temperature fluctuations, strong vibrations, dust or dirt contamination, condensation moisture and resulting corrosion.

For example, FR 1548650 shows a connector for a conductive layer disposed in an insulation according to the preamble of claims 1 and 15, respectively.

With increasing competition in the automotive market, increasing pressure on the manufacturing costs, the reduction must bring no loss of quality or lasting durability with it. It has consequently been constantly trying to achieve further improvements in the field of electrical wiring and contacting. The transition from individually routed cables or prefabricated cable bundles to film conductors, which are also referred to as flex foils, brought significant progress, in particular in the field of display instruments and fittings for motor vehicles. Such flexible Foils, in which usually several electrical conductors are arranged flat, on the one hand are not susceptible to vibration and on the other hand, even under the most difficult conditions by their bending capabilities and free configurability of the conductor arrangement used. In addition, contact fields can be dimensioned, which are formed congruent to corresponding terminals on the fittings or printed circuit boards. However, for these conductors, conventional methods of making an electrical connection are time consuming and costly. In general, the contact surfaces of the Flex Foils were connected by soldering both electrically and mechanically. Particularly detrimental here is that introduced in solder joints vibrational forces tend to break this or precipitated in the finest cracks moisture, which can lead to corrosion germs.

The invention is therefore based on the object to avoid the disadvantages described above and to provide a low-cost, easy-to-connect electrical connector and a corresponding method for producing an electrical connection. It should also be made with minimal installation effort a high quality and durable electrical connection.

This object is achieved in a surprisingly simple manner by the features of claims 1 and 15.

If a force is exerted by at least one contact pin for establishing an electrical contact with at least one conductor, which gives both a mechanical contact of the conductor to the contact pin and the provision of an electrical contact, soldering connections can generally be dispensed with. The installation of the contact pin can in principle take place in an area which is completely free of the flexible film or is coated, for example, on the back of the conductor with the film. Furthermore, partial regions of the front contact surface of the conductor can also be coated with foil as long as at least exposed windows of the conductor remain in contact with the contact pin.

If the contact pin penetrates the electrical conductor or the electrical conductor and a portion of the flexible film such that a substantially defined bending of the conductor and / or the flexible film is generated, predefined bending moments can be generated with these associated restoring forces which are at least partially within the elastic bending region of the conductor and / or the film are. As a result, registered in the film vibrations or shocks can be absorbed elastically, without causing a break in the conductive connection. Especially in the field of digital signal transmission, where lying in the nanosecond signal edges for the detection of signal contents, a temporally really uninterrupted connection of great advantage.

If, when the contact pin is mounted, the conductor or the conductor, together with the flexible foil, is applied both to the contact pin and to an annular shoulder of the dielectric housing of the connector, a predefined rounding of the annular shoulder reliably avoids kinking and a soft outlet of a preferably funnel-shaped bending of the conductor and the flexible film are created. A funnel-shaped bending is of great advantage, since first elastic restoring forces are provided in each direction of the plane of the film and beyond a displacement in the axial direction can initially be elastically intercepted by an expansion of the funnel angle and in consequence by a harmless displacement of the conductor relative to the contact pin ,

However, an advantage is a device for mechanically holding the conductor or the film together with the conductor through which the conductor is mechanically held in the receptacle at a substantially annular area when driving the contact pin. Does this means for holding a lateral shoulder, which is pressed so when pressing the contact pin down and to the side that comes between the electrical conductor and the receptacle to a press fit, vibration forces in the axial direction can be completely absorbed. Moreover, at the same time a closed volume can be created within the interference fit, which permanently excludes the occurrence of moisture or dirt and subsequent corrosion at the site of electrical contact.

In a preferred manner, although the contact pin is pressed during assembly by an associated opening or thinning in the film such that it sits in the assembled state in a funnel-shaped flared opening or opened thinning of the film. If, however, the contact pin is formed conically or pointedly ending, it can be driven in an alternative embodiment according to the invention by any area of the elastic film with electrical conductor embedded therein, so that both the film and the conductor are pierced and similar the corresponding dimensioning of the diameter of the contact pin generates the desired defined force relationships between the electrical conductor and the contact pin.

Advantageously, a second means for strain relief is further provided, which is preferably arranged displaceably in the same direction as the contact pin, said second means for strain relief generates a defined bending of the flexible film, in a particularly preferred embodiment a Deflection by 90 degrees causes. As a result, in the plane of the film extending vibrations or pulses are almost no longer transmitted to the angled contacted end.

It is also within the scope of the invention to make the connection of the film L-shaped, so that the kink between the legs of the L leads to a further reduction in the transmission of mechanical forces.

In a particularly preferred embodiment of the invention, a preassembled position is assigned to both the contact pin and the second device for strain relief, in which they are held by snapping or static friction and from which both can be brought in a common direction in its mounted position. For this purpose, it has proven particularly useful to hold the contact pin in an associated channel within the dielectric housing of the connector and a locking element on the rider of the second strain relief, which provides a resistance against accidental closure in its pre-assembled position.

Another extremely desirable simplification of the assembly of the electrical connector results from the fact that this holder means for fixing the position and permanent securing of the connector to an associated board, said holding means projecting on the underside of the housing of the connector with its longitudinal axis in the direction of displacement of the contact pin and their carry housing-distal end latching means which can produce a latching connection to a board or an associated recording. This makes it possible to attach the connector with a simple pressure at its desired mounting location.

If the housing-distal ends of the holding devices of the connector have conical regions, this results in a Self-centering effect, which improves both automation and manufacturing reliability.

In addition, if the electrical connector has a lateral transport support which is releasable by a displacement of its housing, all assembly steps, namely removal of the connector from its mounting bracket, making electrical contact with encapsulation of the resulting contact area, mechanical holding, closing a first and a second Strain relief, attaching the electrical connector at its final mounting location and making an electrical connection from the connector to a printed circuit board in a single step are performed. The electrical contact between the connector and printed circuit board or associated fitting can be made by driving the contact pins into plated-through holes in the printed circuit board or fitting.

Fig. 1

eine perspektivische Ansicht einer ersten erfindungsgemäßen Auführungsform des elektrischen Verbinders,

Fig. 2

eine perspektivische Ansicht einer zweiten erfindungsgemäßen Ausführungsform des elektrischen Verbinders,

Fig. 3

eine perspektivische Ansicht einer dritten erfindungsgemäßen Ausführungsform des elektrischen Verbinders,

Fig. 4

einen Querschnitt im Bereich des Kontaktstiftes in dielektrischem Gehäuse verlaufend mit jeweils in vormontierter Stellung angeordnetem Kontaktstift und Reiter der zweiten Zugentlastung,

Fig. 5

einen Querschnitt gemäß Fig. 4, bei welchem die erste Zugentlastung in deren montierten bzw. zugentlastenden Zustand verbracht und anfänglicher elektrischer Kontakte zwischen dem Kontaktstift und dem Leiter hergestellt ist,

Fig. 6

einen Querschnitt gemäß Fig. 4, bei welchem der Kontaktstift vollständig durch den elektrischen Leiter hindurchgetreten und elektrischer Kontakt zum Leiter hergestellt ist,

Fig. 7

eine Querschnittsansicht in einer zu Fig. 4 parallel versetzten Ebene außerhalb des Kanals für den Kontaktstift,

Fig. 8

eine Seitenansicht des erfindungsgemäßen elektrischen Verbinders mit geschlossener zweiter Zugentlastung.

The invention will now be described in more detail by means of preferred embodiments and with reference to the accompanying drawings, in which:
Show it:

Fig. 1

a perspective view of a first embodiment of the invention of the electrical connector,

Fig. 2

a perspective view of a second embodiment of the invention of the electrical connector,

Fig. 3

a perspective view of a third embodiment of the invention of the electrical connector,

Fig. 4

a cross section in the region of the contact pin in a dielectric housing extending with each arranged in the preassembled position pin and Rider of the second strain relief,

Fig. 5

4 shows a cross section according to FIG. 4, in which the first strain relief is brought into its mounted or strain-relieved state and initial electrical contacts are made between the contact pin and the conductor;

Fig. 6

4 shows a cross section according to FIG. 4, in which the contact pin has completely passed through the electrical conductor and electrical contact is made with the conductor,

Fig. 7

4 shows a cross-sectional view in a plane offset parallel to FIG. 4, outside the channel for the contact pin,

Fig. 8

a side view of the electrical connector according to the invention with closed second strain relief.

For ease of understanding, in the following detailed description, like or similar components are designated by the same reference numerals.

Reference will first be made to FIG. 1, in which the connector according to the invention denoted as a whole by 1 can be seen obliquely from above in a perspective view. The preferably produced by injection molding dielectric housing 2 has two substantially cylindrical channels 3, 4 for receiving a respective contact pin 5 on. The channels 3, 4 comprise at least one region of defined diameter, within which the contact pin 5 is held with defined static friction.

At the ends of its two longitudinal sides, the dielectric housing 2 forms guide channels 6, 7 which are open to the side and can be held in an associated transport holder with defined static friction or latching, so as to form a transport holder for the connector 1. The Transport bracket can be solved by a shift in the direction shown by the arrow A in Fig. 4 direction of displacement of the contact pin 5.

Below the housing 2 extending holding devices 8, 9, 10, 11 for fixing the position and daurerhaften securing the connector to a board, not shown in the figures or recording, which has the holding means 8, 9, 10, 11 associated openings. The longitudinal axes of the holding devices 8, 9, 10, 11 also extend in the direction indicated by the arrow A displacement direction, wherein the housing distal end of the holding means 8 and 10 carries locking means which can establish a latching connection with the board, not shown, or associated receptacle. This locking is made by inserting the connector 1 in the direction indicated by the arrow A in the associated openings or recordings.

Although holding devices are shown in the figures 1, 2 and 3 only at the ends of the longitudinal sides, it is within the scope of the invention in embodiments having a large number of contact pins 5, in the middle or at several points of the housing 2 holding devices for Keep the connector 1 provided.

FIGS. 2 and 3 show further embodiments according to the invention which are intended to accommodate respectively 12 or 18 contact pins 5 in their channels 3, 4.

At the front of the housing 2 there is a recess 12, which is used either for stabilization or centering of the housing 2 in a transport receptacle, which is not shown in the figures, or for a tool for pushing out the housing 2 from the transport bracket in its final fastened position can be used.

Further, by the recess 12, which exposes a piece of the receptacle 16, both optical and also mechanical and / or electrical detection of the position of the flexible film 14 on the stop 18 are made.

Reference is now made to Figures 4 to 6, in which the process of producing an electrical contact and the closing of the first strain relief 13 with subsequent encapsulation of the contact region 14 is shown. When pressing down the contact pin 5 in the direction of the arrow A, this meets with its lower conical or pointed end on the first strain relief 13, which is designed as an annular circumferential shoulder, which narrows the inside width of the channel 3. The flexible film 14 with the electrical conductor 15 disposed therein is inserted into the slot-shaped receptacle 16 such that an opening 17 in the conductor 15 and the film 14 is arranged concentrically under the channel 3.

This arrangement can be achieved in a simple manner by appropriate design of the flexible film, the film then abuts both an end-side stop 18 as well as by lateral, not shown in the figures boundaries of the slot-shaped receptacle 16 is centered.

As shown in Fig. 5, the downwardly extending contact pin 5 expands the annular first strain relief 13 down and to the side so that the flexible film 14 is pressed with the therein conductor 15 on the lower side of the slot-shaped receptacle 16, whereby a solid mechanical support between the flexible film 14 and the receptacle 16 of the housing 2 is generated. In a further embodiment of the invention, this press fit can provide sealing and encapsulating function.

Upon further downward driving of the contact pin 5, this can with its lower conical end in the opening 17th the flexible film 14 and the electrical conductor 15 enter such that it comes to the funnel-shaped deformation of the film 14 and the electrical conductor 15 shown in Fig. 6.

When driving the contact pin 5, the film 14 is then at the lower side of the annular shoulder 20, which has a defined rounding, so as to produce a predefined, respectively adapted to the flexible film 14 and the electrical conductor 15 deformation. Furthermore, this can on the one hand avoids cracks and bending breaks and on the other hand, a defined elastic deflection can be generated, the restoring forces within the contact area 21 ensures a safe investment of the electrical conductor 15 on the contact pin 5.

It is also within the scope of the invention, instead of the opening 17 to use a thinned area 19 without opening 17 with a tapered contact pin 5, which intersects with its pointed lower end itself an opening in the film 14 and the conductor 15. The choice of the diameter of the contact pin 5, and the thickness of the film 14 and the conductor 15 can in this case be coordinated so that the resulting contact area 21 provides the desired always safe investment of the conductor 15 on the contact pin 5.

In a further alternative embodiment of the invention, the lower end of the channel 3 has a constriction 22, which ensures a tight or sealing contact with the contact pin 5, so that the contact region 21 is sealed substantially hermetically to the outside.

If the contact pin 5 driven further down with a wide planar tool, the tool enters the area of the upper edge of the rider 23, which forms part of the second strain relief, and this is together with Move the contact pin 5 down.

In the illustrated in Fig. 4 preassembled position of the rider 23 and the contact pin 5 are both secured against displacement down. The static friction of the contact pin 5 holds this safely in the channel 3 and the detent 24 of the rider 23 abuts with its wedge-shaped contact surface on the housing 2.

The tab 23 has a contact pin 5 facing, in cross-section T-shaped region which is arranged longitudinally displaceable in a likewise T-shaped recess of the housing 2 in the direction of arrow A.

As shown in FIGS. 7 and 8, when the assembly tool advances with its flat lower surface in the direction of arrow A, the rider 23 is slid to its lower latched position, in which the latch 24 is substantially L-shaped in cross-section Section 25 of the housing 2 engages behind.

In the assembled position of the contact pin 5 and the tab 23 shown in Fig. 8, the flexible film 14 is deflected with the conductors 15 disposed therein by substantially 90 degrees, with vibrations or shocks within the film 14 and the conductor 15 is practically no longer in the interior of the housing 2 are transmitted. In a further embodiment according to the invention, the flexible film 14 with the conductor 15 arranged therein can have an L-shaped section which, due to its deflection by 90 degrees, again significantly reduces the transmission of vibrations or shocks.

In the mounted position shown in Fig. 8, the contact pin 5 is moved out of the housing 2 downwardly protruding, so that a not shown in the figures board with arranged through-contacted openings can be penetrated by the contact pin 5 with a narrow radial contact. Depending on the further embodiment according to the invention, a solder connection to the contact pin 5 can be produced as a result, or radial elastic restoring forces of the plated-through opening can already provide a secure electrical contact. Vertical forces or vibrations running perpendicularly to the longitudinal axis of the contact pin 5 can be securely absorbed in the mounted position by the holding devices 8, 9, 10, 11 of the housing 2.

The assembly of the connector 1 to the flexible film 14 with the conductor 15 arranged therein can be done either step by step or a single step

If the assembly is made in a single step, the static friction of the pin 5 within the channel 3 and the forces occurring during the passage of the contact pin 5 through the film 14 and the conductor 15 can be adjusted so that the housing 2 under the action of a in the direction of Arrow A down passing assembly tool remains in its transport bracket until the pins 5 abut the opening 17 or the thinned area 19, thus fixing the film 14 with the conductor 15 within the receptacle 16, after which the housing 2 from the transport bracket down is shifted out so that the holding devices 8, 9, 10, 11 pass through openings of a board or in an associated recording, wherein the holding means 9, 11 with their conical areas lead to a self-centering adjustment. Thereafter, by the mechanically fixed contact of the housing 2 on the board or in the associated receptacle, the increased forces when closing the first strain relief and the expansion of the electrical conductor 15 and the flexible film 14 are received by the board or the associated recording. As a result, the contact pin 5 becomes the electrical connection to the board produce.

In accordance with the invention, however, a connector which has already been prefabricated with the flexible film can also be pushed out of the transport holder and inserted into the circuit board.

reference numeral

1

electrical connector

2

dielectric housing

3, 4

channel

5

pin

6.7

Guide channels of the transport device,

8,9,10,11

holding devices

12

depression

13

first strain relief

14

flexible film

15

electrical conductor

16

admission

17

opening

18

attack

19

dilute area

20

annular shoulder

21

contact area

22

Constriction or sealant

23

equestrian

24

locking lug

25

L-shaped section

Claims (20)

1. Electrical connector for producing a connection to at least one conductor which is substantially arranged in a flexible foil,
   comprising

   - a dielectric housing with a receiving area (16) for the insertion of the flexible foil and the at least one conductor, wherein the dielectric housing comprises a cylindrical duct (3),

   - at least one contact pin (5) for producing an electrical contact with the at least one conductor (15), wherein the contact pin (5) exerts a force on the electrical conductor (15) and / or the flexible foil (14), wherein this force ensures mechanical abutment of the conductor (15) against the contact pin (5) and the provision of an electrical contact,

   - a first device (13) forming a strain relief element for the mechanical holding of the conductor (15) or the foil (14) together with the conductor (15), through which, when the contact pin (5) is driven in, the conductor (15) or the foil (14) together with the conductor (15) is mechanically held on a substantially annular region (13),

   characterised in that the strain relief element (13) is formed as an annular shoulder which narrows the inside width of the duct (3) in such a manner that the downwardly running contact pin expands the annular strain relief element (13) downwardly and to the side so that the flexible foil (14) with the conductor (15) located therein is pressed on the lower side of the slit-like receiving area (16).
2. Electrical connector according to claim 1, characterised in that the contact pin (5) goes through the electrical conductor (15) or the electrical conductor (15) and a section of the flexible foil (14) in such a manner that a substantially defined bending of the conductor (15) and / or the flexible foil (14) is produced.
3. Electrical conductor according to claim 1 or 2, characterised in that, when the contact pin (5) is assembled, the conductor (15) or the conductor (15) together with the flexible foil (14) lie against the contact pin (5) and against an annular shoulder (20) of the dielectric housing (2).
4. Electrical connector according to claim 3, characterised in that the annular shoulder forming the strain relief element, upon pushing-in of the at least one contact pin (5), is pushed downwardly and to the side in such a manner that a force fit is produced within the receiving area (16) between the electrical conductor (15) and / or the flexible foil (14).
5. Electrical connector according to one of the preceding claims, characterised in that the contact pin (5) is arranged in the assembled state so as to go through an opening (17) assigned thereto or a thinned-out area (19) in the foil (14) and in the conductor (15).
6. Electrical connector according to one of the preceding claims, characterised in that the contact pin (5) is formed so as to be conical or sharp at least on its end facing the electrical conductor (15) before assembly.
7. Electrical connector according to claim 6, characterised in that the contact pin (5) is arranged in the assembled state so as to go through a conductor section (19) not provided with a prior opening.
8. Electrical connector according to one of the preceding claims, further characterised by a second device (23, 24) for strain relief.
9. Electrical connector according to claim 8, characterised in that the second device (23, 24) for strain relief is arranged so as to be displaceable in the same direction as the contact pin (5) and produces in the strain-relieving assembled position a defined bending of the flexible foil (14).
10. Electrical connector according to claim 8 or 9, characterised in that the second device (23, 24) for strain relief comprises fastening elements (24) which hold a rider (23) of the second strain relief element in the assembled strain-relieving position.
11. Electrical connector according to one of the preceding claims, characterised in that a pre-assembled position is assigned to the contact pin (5) and to the second device (23, 24) for strain relief, from which pre-assembled position both the strain relief element (23, 24) and the contact pin (5) can be brought in a common direction into their assembled position.
12. Electrical connector according to one of the preceding claims, characterised by a duct (3) in the dielectric housing (2) of the connector (1) for holding the at least one contact pin (5) with static friction to the duct wall.
13. Electrical connector according to one of the preceding claims, further characterised by holding devices (9, 10, 11) for fixing in position and permanent securing of the connector (1) on an assigned board which project on the lower side of the housing of the connector with their longitudinal axis in the direction of displacement of the contact pin (5) and the housing-remote ends of which carry fastening means.
14. Electrical connector according to one of the preceding claims, further characterised by a side transport holder (6, 7) on the connector which can be released through displacement of the housing (2) of the electrical connector (1).
15. Method for producing an electrical connection between a flexible foil (14) guiding an electrical conductor (15) and a connector (1),
    with a dielectric housing with a receiving area for the insertion of the flexible foil and the at least one conductor, wherein the dielectric housing comprises a cylindrical duct (3), and with at least one contact pin (5) for producing an electrical contact to the at least one conductor (15), wherein the contact pin (5) exerts a force on the electrical conductor (15) and / or the flexible foil (14) which ensures mechanical abutment of the conductor (15) against the contact pin (5) and the provision of an electrical contact,
    preferably to a connector as defined in one of the preceding claims, comprising:

    the pushing of a contact pin (5) from a pre-assembled position into an assembly position, wherein a defined deformation is introduced into at least one region of the electrical conductor (15) or the electrical conductor (15) with the flexible foil (14), wherein a permanent electrical connection is formed between the contact pin (5) and the electrical conductor (15),

    and wherein during at least part of the pressing-in process of the contact pin (5) a first device (13) forming a strain relief element for holding is brought out of its pre-assembled position into its assembled strain-relieving position,

    characterised in that

    the downwardly running contact pin (5) expands a strain relief element (13) which is formed as an annular shoulder which narrows the inside width of a duct (3) downwardly and to the side in such a manner that the flexible foil (14) with the conductor (15) located therein is pressed on the lower side of a slit-like receiving area (16), wherein a fixed mechanical hold is produced between the flexible foil (14) and the receiving area (16) of the housing (2).
16. Method for producing an electrical connection according to claim 14 or 15, characterised in that during at least part of the pressing-in process a second strain relief element (23, 34) is brought out of its pre-assembled position into its assembled and secured strain-relieving position.
17. Method for producing an electrical connection according to claim 15 or 16, characterised in that the contact pin (5) is pushed with one end out of the dielectric housing and into an assigned opening in a printed circuit board.
18. Method for producing an electrical connection according to one of the claims 14 to 17, characterised in that the electrical connector is pushed out of a transport holder before, during or after one of the method steps of the claims 14 to 17.
19. Method for producing an electrical connection according to claim 18, characterised in that the electrical connector (1), after being pushed out of the transport holder, is brought with its holding devices (8, 9, 10, 11) for fixing in position into assigned receiving area devices for secured holding.
20. Method for producing an electrical connection according to one of the claims 14 to 19, characterised in that all method steps of the claims 14 to 19 are carried out in a single work stage, particularly through a single displacement process.

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