EP2135331A2

EP2135331A2 - Plug pin

Info

Publication number: EP2135331A2
Application number: EP08706902A
Authority: EP
Inventors: Michael Taller; Joachim Rief
Original assignee: Taller GmbH
Current assignee: Taller GmbH
Priority date: 2007-02-23
Filing date: 2008-02-20
Publication date: 2009-12-23
Also published as: WO2008101485A3; DE112008000295A5; DE102007009422A1; WO2008101485A2

Abstract

The invention relates to a plug pin comprising contact surfaces (2a, 2b) and an area (3) that connects the contact surfaces. The width of the contact surfaces and the connecting area differs.

Description

description

The present invention relates to the preamble claimed and is thus concerned with the manufacture of electrical connections.

Electrical connectors are mass-produced in many areas, such as in consumer devices that are connected to electrical outlets via power lines. The plug used for the connection of power lines to sockets have to offer because of the considerable voltage on the one hand a high degree of security against incorrect operation, destruction and the like; this requires adherence to tightly tolerated standards, the passing of safety and destruction tests, such as the fall-drum tests, etc. On the other hand, plug-in bridges must be provided as mass-produced everyday products, even under considerable price pressure, regardless of the desired high quality.

The provision of cost-effective power lines requires on the one hand that for the power lines to be used connector bridges can be processed quickly, and on the other hand nevertheless the jumper itself is inexpensive to produce, which only low material costs and allows easy processing with a long tool life requiring tools.

- l - The object of the present invention is to provide new products for commercial use.

The solution to this problem is claimed in an independent form. Preferred embodiments can be found in the subclaims.

The present invention thus proposes in a first basic idea a plug pin with contact surfaces and an area connecting them, in which it is provided that the width of contact surfaces and connecting region differs.

A first essential realization of the present invention can thus be seen in that the plug pin, although integral, can be considered as being dissected into its functional elements to provide an increased level of design possibilities for the plug pin design and plug bridge design, respectively. As a result, in the present case, the plug pin can initially be specified with regard to those surfaces which are provided for the actual contact with the mating contacts in a socket of the respective standard, and differences are then permitted on the areas connecting the contact surfaces, which are only for the correct mechanical alignment the contact surfaces have to provide each other and to the contacts in a plug.

It is exploited that the contact surfaces typically significantly larger due to the given relative tolerances of resilient mating contacts in the socket, as it is for those in relation to heating by contact resistance or the like risk-free line of electricity would be required, but at the same time the contact surfaces by connecting them together and in correct alignment with each other holding area are electrically connected, but it is not necessary to form this area massive.

In a preferred variant, the plug pin, as usual in many countries, is generally rectangular. In the case of such a generally rectangular plug pin cross-section or a generally cuboid plug pin basic form, it is particularly advantageous to allow the connecting region to differ from the width of the contact surface. It can be provided without problems that the contact surfaces on opposite sides of the cuboid or the rectangular connector pin are arranged. The connecting region can then be located therebetween and in particular completely covered by the contact surfaces, i. H. especially narrower in cross section than this.

Such a design leads to significant cost savings, because the contact surfaces of the pin must be greater than the rule for mechanical reasons between them to be provided connection area. The mechanically required smaller cross-sections allow at these points a material savings, which, regardless of an optionally required additional use for tools and the like, a total cost savings. In particular, a profiling of the plug pin, ie a plug pin profiling with a lateral recess at the edges, is proposed. In a particularly preferred variant, the connecting region may be formed as a web between the contact surfaces. The width of the web can be selected such that during processing of the plug pin or the later use the contact surfaces of the plug pin can not be tilted against each other by pressure on the outer edges. The plug pin will have approximately the shape of a double-T carrier, wherein the thickness and edges of the middle beam is determined by the aforementioned requirement and the producibility. It should also be noted that also a further profiling of the land area is possible and about tubular plug pins with hollow cross-section would be used. In such, the connecting area in the overall width through the clear area between the side walls is smaller than the width of the contact areas.

Incidentally, it should be noted that it would be possible to arrange the area only electrically between the contact surfaces in order to connect them to one another in an electrically conductive manner, but not thereby to define its spatial position between the contact surfaces. In such a case, for example, the central area could simultaneously serve for crimping. A definition of the plug pin shape would then be possible by encapsulation with plug bridge base material readily.

The bridge formation can be done in different ways. The web can be turned out or milled from the fullness of a rectangular band body, whereby the resulting chip wastes can typically be recycled from brass chips to a recycling, which saves material costs. Alternatively, it is possible and preferred to use an at least largely to use profiled starting material, which forms the web by wire or pultrusion or the like. It should be noted that the web forming can be done from a mechanical point of view. Thus, it would also be possible not only to vary the profile with respect to a purely rectangular pin by recess, but also along the pin length to vary the profiling, which may cause by transverse rib formation on the one hand high material savings, but at the same time an even higher pin stability.

In addition to a contouring of the plug pin to the web formation is typically a einschuberleichtender or defining stop at the top partially rotated, milled and / or punched or formed in other ways.

In a particularly preferred variant of the pin connectors used for a South African and / or British Standard as a pin and can _be both to the phase pins and also used the ground pin there.

On the plug bridge side, the plug pin can have a region for crimping and / or welding and / or riveting a metal sheet, which in turn serves to strike a mains connection strand.

It is particularly preferred if the width of the connecting region is smaller than that of the contact surfaces. It should be noted that the contact surface width is not dimensioned in the rule with respect to the required minimum currents. Furthermore, it is particularly preferred if the plug pin has at least one generally planar contact surface, preferably two generally planar contact surfaces on sides facing away from one another. Generally even here means that contact surfaces may have a curvature or the like, as far as it is standard, but that the surfaces are formed as areas that have a significantly lower curvature than other pin areas.

The pin can be filled at its edges, in particular in training of the pin with web, by molding compound.

The plug pin can be recessed in the region of the plug bridge and / or close to it, ie, facing away from the socket side contact end, and possibly surrounded by plastic material. There is then a plastic-coated stem taper. It should be noted that a plastic encapsulation or a plastic encapsulation profiling is advantageous in two respects, because on the one hand, the stability of the connector pin is increased, which has a positive effect in case drum tests and the like, even if the connector pin experience a significant thinning in web area On the other hand, the operational safety can be increased by the particularly smooth surface. A plastic grout thus allows even greater material savings. It should be noted that, moreover, a reduction of the cross section can be achieved even in this area by perforations of the connector pin. The plug pin of the present invention can be used in plug bridges, with which in turn power lines can be produced, which in turn can optionally be firmly connected to electrical appliances on the load side. Protection is therefore also claimed for connector bridges with connector pins according to the invention, power lines with such connector bridges and electrical appliances with such power lines.

The invention will now be described by way of example only with reference to the drawings. In this is represented by:

Figure 1 is a pin of the present invention in perspective and from the side views. Fig. 2 shows a variant of the plug pin of FIG.

1 with thinned shaft;

FIG. 3 shows plug pins corresponding to those of FIGS. 1 and 2, but with different shapes.

4 Shaped socket-side end; Fig. 5a, b, c a plug bridge in various perspective views with plug pins of FIG. 3;

5d, e, f show a plug bridge in various perspective views with plug pins according to FIG. 4;

6a, b, c show a plug bridge in different perspective views with plug pins according to FIG. 1 ;

FIGS. 6d, e, f show a plug bridge in different perspective views with plug pins according to FIG. 2;

Fig. 7 and other perspective views of Fig. 8 plug bridges with plug pins according to the present invention; Fig. 9 to 11 a further variant of the connector bridge according to the present invention.

According to Fig. 1, a connector pin generally designated 1 comprises contact surfaces 2a and 2b, which are in electrically conductive connection with each other through a connecting portion 3. The width of the region 3, represented by arrow A in FIG. 1, differs from the width of the contact surfaces, represented by arrow B in FIG. 1.

The plug pin 1 is formed in the present case of brass, which is supplied as profiled wire or tape processing to plug pins. The profiling of the plug pin 1 forming brass wire is such that the contact surfaces 2a, 2b and a connecting region defining recess 4 have been made during wire drawing. The production of the Messingroh- material by pulling a wire also allows to provide the recess 4 with a non-conical shape, as can be seen by the groove 4a, 4b near the side edge 2c and 2d. The plug pin 1 may be nickel plated in the usual way, the nickel plating can be applied by the pin after completion of the molding.

At the plug-side end 5 in use of the plug pin 1, a frusto-conical surface 6 is provided here. The size of the truncated cone 6 is sufficient to define the plug pin position when pouring the pin into a plug base plate by means of a mold. At the end 7 of the plug pin 1 facing away from the socket in use, a milled recess 8 is led through the narrow sides 2c, 2d of the plug pin, which extends into the recess 4 in order to subdivide the surfaces 2 on the one hand the contact surface areas 2a, 2 b, which after encapsulation of the plug pin protrude from a plug bridge base plate on the plug side, compare FIGS. 6 b and on the other hand regions 2 e which extend into or above the plug bridge base plate after encapsulation and are shaped as shown in such a way that the fixation in the base plate is favored. At the end of the plug pin facing away from the socket side after potting, a rivet lug 9 is provided, which protrudes beyond the plug bridge base plate 10 and to which a brass plate 12 leading to crimp connections IIa, IIb, 11c of the plug bridge is riveted or otherwise electrically conductive and mechanical can be firmly fixed.

The contact surfaces 2a, 2b are formed in the present case as a flat boundary surfaces over the entire pin width. They extend in the installed state of a the insertion of the plug into the socket favoring bevel, which is formed in the plug pin shown in Figure 1 by a corresponding standard conforming Vergussmassenformung around the truncated cone 6 around, as shown at reference numeral 13 in Fig. 6b. up to the socket-side surface 10a of the connector bridge plate 10th

The material thickness at the surfaces 2 a, 2 b is at the

Narrow side 2c, 2d of the pins chosen so that on the wall of the thickness C even with heavy loads on the edge For example, between surface 2a and 2d no deformation of the pin occurs. This stability can also be promoted by a corresponding profiling of the recess 4.

The recess 4 is chosen so that the remaining web, which has the width A, is wider than the base of the truncated cone 6a, so that in the production of the pin of brass wire or strip material by milling a cut to length accordingly the truncated cone 6 can be formed. The same applies to the approach 9 on the opposite side.

While the plug pin of Fig. 1 is primarily preferred for ground pins, so those pins that get in contact with the ground conductor in the socket when using the jumper, here is the illustrated pin pin of Fig. 2 for the phase conductors (0 and phase) of a three-phase protective contact plug, as it is used using square plug pins, for example in the United Kingdom used.

The plug pins of FIGS. 1 and 2 differ, in addition to their outer contours, with which standardized dimensions are realized, essentially by a shank taper 14 in the phase plug pin of FIG. 2. This shank taper is achieved by milling the shaft in a region, which in use is located between the plug bridge base plate and the contacting end of the plug pin. The recess 14 in the region is selected so that when pouring the plug pin in the Steckerbrückenhersteilung the tapered area with potting compound is completely flowed, and is ensured by appropriate contact of the plug pin 2 in an injection mold, that flat surfaces between the contact end 2 a, on which the metal surface remains visible and an electrical contact can take place, and the area of the over-molded shank taper 14, in FIG. 6 f, is flush and level with 2 a 2. This design has the advantage that a further reduction of the brass material insert in the connector pin can be achieved without affecting the electrical properties. The brass material to be removed from the profiled brass wire starting material blank for shank taper formation in the region of the shank taper can be readily fed to a recycling process.

It should be noted that the recess 4 'is profiled differently in the plug bridge pin of Fig. 2 than the recess 4 of the connector pin of Fig. 1, in that the grooving 4a, 4b not provided in the connector pin of Fig. 2 is and the recess has a different contour. It is explicitly pointed out that in the plug pin of FIG. 1, a recess with a general circular segment shape (apart from the grooves 4a and 4b) is made, which comprises a circular segment extending beyond 180 °.

It should be noted, however, that the recesses shown in each case are not intended to be determined by the drawing for specific applications or pen areas of use, but instead are given in an exemplary manner in order to design objects.

- II - show possibilities without limiting the expert here to the variants shown.

FIGS. 7 and 8 or FIGS. 5f and 6f show in comparison that it is possible during the production of the plug bridge to completely fill the recess with potting compound between the plug-in base side of the bridge plate 10a and the end edge or to penetrate the potting compound to allow the depression only partially. If only a partial penetration of the potting compound into the plug pin recess 4 is to be made, then it is preferable to carry out a recessing profile which promotes demolding of the plug bridge from the casting mold; in such a case, therefore, the variant of FIG. 2 is preferred. In contrast, over the entire length of the plug pin base projecting beyond the plug pin base molding with casting compound, a profiling according to FIG. 1 with grooves 4a, 4b or the like is preferred because here the casting material urging into the recess remains solidified even in the case of shrinkage is very securely fixed.

Further variants of plug bridge pins are shown in FIGS. 3 and 4. 3 corresponds to a plug pin which is made from the same starting material as the plug pin of FIG. 1 and accordingly also has the same recess 4 provided with creases 4a, 4b and thus intended for complete filling with casting compound.

In contrast to the plug pin of FIG. 1, however, no truncated cone 6a is turned off on the plug side, but it is Insert surfaces punched or pressed from the solid material. This has the consequence that in the plug bridge production with the plug pin of Figure 3, the insertion-facilitating bevels 13 are not formed by injection molding, but in one piece with the pin. Correspondingly, the plug pins of FIG. 2 and FIG. 4 again differ in that a solid Absσhrägung is provided instead of a stop-defining truncated cone. As in the case of the plug pin of FIG. 3, a correct position of the plug pin in an injection mold during manufacture of the plug bridge plate is ensured by a stop edge 13c lying between the bevel faces 13a, 13b.

Connector bridges according to the invention can be produced as follows:

First, a brass material with Eintiefungsprofilierung is provided and cut to length. The cut-to-length portions are machined to provide the socket-side ends with bevels, truncated cones, or other stop definition means in a plug bridge mold, to provide shouldering for fixation in the plug bridge form, to form the lugs 9, etc. Mes made of solid material in the manufacture of connector pins - Singing chips are recycled.

The pins are surface treated as required, for example, nickel plated, and then singulated and aligned so that they can be placed in an injection mold. In this injection mold, they are encapsulated to form the plug bridge base plate, as required, the injection molding material penetrates into the recess 4 and forms the chamfers 13 as required on the insertion side end of insertion. The shape of the recess 4 can be achieved that the casting material freely and reproducibly flows to those places where it is needed in the finished connector bridge. After the plug bridge base plate is formed, punched brass plates can be struck on the plug pins, which in turn have crimping ends for the connection to strands of a power line in the usual way; The brass stop plates can be connected in a known manner with fuse holders as required by the standard. Reference is made to the preferred embodiment of a security area according to published patent rights of the present Applicant. The crimp areas of the damaged brass sheets can moreover be covered by a preferably designed as a hinged lid area, as known from the application. The attachment of strand feeding funnels and the like, as will be apparent to those skilled in the art, is readily possible; Here, too, reference is made to corresponding IPRs by the present Applicant.

After completion of the connector bridge can be posted to this stripped strand ends a power line, in particular crimped and done with the ailing strand ends encapsulation of the connector bridge plate to form a handle body of a power plug.

While it has been described above that rivets 9 are provided at the ends remote from the socket side of the plug pins, this is obviously not mandatory. It is particularly possible, the plug pins on the side facing away from the socket side end so to form that a direct connection with strands of a power line is possible. In particular, the plug pins can be flared trumpet-shaped or funnel-shaped at the end to allow direct crimping.

While material may be milled or turned away from the above, it is not absolutely necessary to square the area between the front contact end of the plug pin for making contact with the socket and the rear portion for striking a power line or a transition piece to a power line. As shown on the previously discussed figures corresponding embodiments. In particular, it is possible to provide the intermediate region between the contact end and the end of the plug pin facing away from the socket with a different cross section, in particular with high roundness, optionally a variation, etc., whereby further material can be saved. Corresponding embodiments are shown in FIGS. 9 to 11.

Claims

claims

1. plug pin with contact surfaces and an area connecting them, characterized in that the width of contact surfaces and connecting region differs.

2. pin according to the preceding claim, characterized in that the pin has a generally rectangular cross-section.

3. pin according to one of the preceding claims, characterized in that the contact surfaces are arranged on sides facing away from each other.

4. pin according to one of the preceding claims, characterized in that the connecting region is covered by the contact surfaces.

5. pin according to one of the preceding claims, characterized in that the connecting region is formed as a web between the contact surfaces.

6. Plug pin according to the preceding claim, characterized in that the web is recessed by profiling of the Steersterbusausgangsmaterials, in particular by using profiled Steckerstiftausgangsmateri- than.

7. pin according to one of the preceding claims, characterized in that the pin milled, turned and / or stamped areas.

8. pin according to one of the preceding claims, characterized in that an area is rotated to the web formation and / or milled, in particular a running between contact surfaces side edge is recessed.

9. pin according to the preceding claim, characterized in that an area for tip contouring is rotated, milled and / or punched, in particular for stop and / or Einschubtiefedefinition.

10. Plug pin according to one of the preceding claims, characterized in that it is dimensioned for a plug South African and / or GB standard, preferably as a plug pin for a ground and phase connection.

11. Plug pin according to one of the preceding claims, characterized in that it is plug-connector side for crimping and / or welding a metal sheet is formed, via which strands of a mains connection cable can be stopped.

12. Plug pin according to one of the preceding claims, characterized in that the width of the connecting region is smaller than that of the contact surfaces.

13. pin according to one of the preceding claims, characterized in that the contact surfaces are generally flat.

14. Plug pin according to one of the preceding claims, characterized in that the plug pin in the connection tion area between the use plug-side tip and a plug base plate in which the pin is to use, filled with casting compound and / or fillable.

15. connector bridge with at least one connector pin according to one of the preceding claims.

16. Power line with a plug bridge according to one of the preceding claims.

17. Electrical appliance with a power line according to the preceding claim.