EP2446509B1 - Electrical plug connector - Google Patents

Description

Area

An electrical connector will be described below. In particular, it is an electrical connector with a contact element, which has a contact lamella basket. In this case, the contact lamella basket has at least two contact zones. Under a connector is understood here according to the usual definition optionally a plug or a socket. As a result of the at least two contact zones on the contact lamella basket, a voltage drop at contact surfaces between a plug and a socket contacting it can be reduced. However, due to their shape or deformation, contact lamella baskets tend to concentrate the electric current flowing through them onto a few contact lamellae.

Technical background

The document EP 1 478 055 A1 describes a contact lamella basket of an electrical connector whose contact blades have at least two arcuate portions with opposite curvature sense. As a result, a contact blade with three arcuate sections is shown in simplified form, of which the two outer sections - seen from the inside of the contact blade basket - are convex, whereas the middle section is concave. Now, if the plug is inserted into the contact lamella, this touches the two outer sections, whereby the contact blades are deflected radially.

In DE 10 2005 017 988 B3 is described an electrical contact sleeve having a plurality of elongated spring elements for electrically contacting a male member and a, the contact sleeve surrounding outer contact socket. The longitudinally elongated in the axial longitudinal direction spring elements have in axial longitudinal distance from each other at least two tapering sections for Vielpunktkontaktierung of a plugged into it plug element. In addition, they have at least two consecutive in axial longitudinal expansion portions for Vielpunktkontaktierung an outer contact socket. In this case, the widening portions are convexly curved while the tapering portions are concavely curved.

problem

In the EP 1 478 055 A1 Although described contact blade form allows for many coupling cycles a constant contact force, however, it can lead to a one-sided load on the contact blades. With an uneven contact along the circumference, which arises as a result of manufacturing tolerances, wear or by an applied to the line or the cable shear force, the current transition focuses on individual contact blades. This can cause a strong heating of the current-carrying contact blades. Since the individual contact blades are separated by air gaps, the resulting heat loss can be distributed only insufficient. In addition, the contact blades are usually made of a material having a positive temperature coefficient; Thus, the electrical resistance of the contact blades increases with temperature.

A major disadvantage of in DE 10 2005 017 988 B3 described contact sleeve is in the double contact resistance, since a voltage drop occurs both at the contact points between the outer contact socket and the spring element and the contact points between the spring element and plug. That the contact resistance increases due to fretting corrosion and other signs of wear is particularly critical for this form of contact sleeve.

document DE 10 2004 002 404 B3 discloses a contact bushing and an associated spring element and a method for the production thereof. The spring element is arranged in document D1 in a receptacle of a contact socket. The spring element is designed annular and has a plurality of spring tongues, which are arranged at a distance from each other. The spring tongues extend from an annular base portion surrounding the spring element, curved inward toward the center of the spring element. In this case, the spring tongues, which are located from the base portion in the upper region of the spring element, form a first contact region, and the spring tongues, which are located from the base portion in the lower region of the spring element, a second contact region. The spring element is formed from a sheet metal strip, wherein the base portion can be bent or connected to form a closed ring, for example by welding, or can remain open, so that the base portion of the spring element has a gap. The spring tongues of the first and second contact regions are connected to one another via the base section.

Another disadvantage of the known contact lamella baskets is that the elasticity of the materials used, usually copper or copper alloys such as beryllium copper, decreases with increasing temperature. This results in a lower spring action and thus in a lower contact force. Thus, a lower elasticity also causes an increasing contact resistance.

Since these adverse effects increase by the temperature dependency itself, there is a risk that the connector will be damaged or destroyed due to an overload. In addition, the contact resistance increases over the life of the connector and the elasticity of the contact blades decreases. Therefore, when designing a safety margin must be provided to prevent damage to the connector. As a result, the contact lamella baskets must be oversized and / or special galvanic coatings must be used to reduce the contact resistance.

task

Thus, the task for an electrical connector to provide a contact element with a contact lamella basket whose geometry allows a uniform distribution of the current flowing through the connector electrical current and the heat loss and at the same time is less prone to temperature increases.

solution

To solve this problem, a connector according to claim 1 is proposed.

Due to its configuration, the contact lamella basket explained below is suitable for minimizing the electrical voltage drop at the contact points and at the same time distributing the electric current uniformly over the entire contact lamella basket.

The intermediate wall between the contact zones of the contact lamella basket enables a uniform distribution of the electrical current and the heat over the entire circumference of the contact lamella basket. The intermediate wall can extend over the entire circumference of the contact lamella basket or only over a part thereof. In addition, it can be interrupted by a separating slot or be continuous. The intermediate wall can thus increase the spring action of the entire contact lamella basket, so that the spring force - and thus the current flow - is distributed uniformly over the circumference of the contact lamella basket. This results in a clear advantage over the prior art, since a current concentration is effectively avoided. In conjunction with the higher spring force of the contact lamella basket thus an additional safety reserve is provided.

In addition, a spring element can be provided which applies a force acting transversely to the longitudinal direction of the connector force on at least one of the contact zones of the contact lamella basket. If the connector is part of the socket, the force acts - in relation to the longitudinal axis of the connector - radially inward. If the connector is part of the connector, the force acts radially outward. The contact basket and the spring element may be separate components.

The spring element may additionally comprise at least one spring blade for each contact zone of the contact blade cage. Likewise, the spring element can have an intermediate wall between the spring lamellae provided for the respective contact zones.

If the spring force of the spring element acts radially inwardly, the spring element can be designed such that it at least partially surrounds the contact lamella cage in the circumferential direction. Since the spring force of the spring element and the spring force of the contact lamella basket are the same direction, the contact force can be increased by the spring element. Since a higher contact force reduces the contact resistance, a further safety reserve is provided by the spring element.

In one embodiment of the connector, the contact blades of the different contact zones are arranged offset from one another in the circumferential direction. Additionally or alternatively, the contact blades of one or all contact zones may be arranged obliquely to the longitudinal axis of the connector.

The connector may be either a socket or a plug. Since the contact resistance between the plug and socket is reduced by the shape of the contact lamella basket, the contact lamella basket can be made of a non-alloyed metal without a special surface coating. Alternatively, it is also possible that the contact region or the entire base body has a surface coating, for example made of tin or a tin alloy. Due to the good electrical properties, copper or copper-containing alloys are used as material for the contact lamella basket.

The spring element may, but need not be, designed to conduct current. Therefore, for the spring element and a material with low electrical conductivity can be used, which is selected based on mechanical or manufacturing properties. The spring element can be made of metal, for example steel, stainless steel, or plastic.

Thus, the spring element and the contact lamellae basket can be formed of different materials. In one embodiment, the spring element may be made of steel and the contact lamellae basket of copper.

The contact blades can also be designed so that the cross section of the contact blades tapers toward the middle, so that in the middle of the contact blades the distance to the adjacent contact blades is greatest. Additionally or alternatively, an embossed contact point can be provided on each contact blade. These contacting points can be located on the inside, the outside or on both sides of the contact lamella basket. Through the contact points on the outside can the spring force of the spring element can be specifically introduced into the contact blades. If the contacting points are located on the inside, then the contacting points form a defined current transition between coupled connectors.

In one embodiment, the contact lamellae basket is designed as a stamped and bent part. Also, the spring element may be designed as a stamped and bent part.

The front part of the contact lamella basket can be designed so that interruptions are provided in a closing ring. Additionally or alternatively, recesses may be provided in the transition region between the contact lamella basket and the solid part of the base body. Due to the interruptions and / or recesses, the spring force of the contact blades can be additionally increased.

In one embodiment, the intermediate wall may be interrupted at least once. The at least one interruption of the intermediate wall can be provided in extension of a long recess. In this case, the at least one interruption of the intermediate wall can be provided obliquely to the longitudinal direction of the connector.

The main body of the connector may have a separating slot. The separating slot in the main body of the connector can run for example in the longitudinal direction of the connector. The spring element may also have a separating slot. The separating slot in the spring element can run, for example, in the longitudinal direction of the spring element. The separating slot in the main body of the connector can pass into a recess or a long recess.

In one embodiment, the separating slot of the spring element can be arranged so as to be secure against rotation relative to the separating slot of the contact lamella basket. In this case, the separating slots of the contact lamella basket and the spring element can be diametrically opposed.

The main body of the present connector can be connected in various ways to an electrical conductor, for example, a crimp, a screw, a screwless clamp connection, a insulation displacement connection, a flat connector a winding connection, a welded connection or a press-in connection may be provided.

Also, the contact lamella basket is adapted to be used in conjunction with any plug geometry. Although only round plug are shown in the figures shown, the present invention, for example, suitable for a rectangular plug.

It is possible to use the contact lamella basket per se or to install it in a larger unit. It is not necessary that the contact lamella basket is part of the main body of the connector.

The connector may have a plurality of contact lamella baskets.

Brief description of the figures

• Fig. 1 zeigt eine Ausführungsform des Steckverbinders mit einem Kontaktlamellenkorb.
• Fig. 2 zeigt eine Ausführungsform des Federelements.
• Fig. 3 zeigt einen Steckverbinder, wobei das Federelement den Kontaktlamellenkorb umgreift.
• Fig. 4a zeigt eine erste Ansicht einer Ausführungsform mit langen Aussparungen.
• Fig. 4b zeigt eine zweite Ansicht der Ausführungsform mit langen Aussparungen.

Hereinafter, the connector will be explained with reference to figures.

• Fig. 1 shows an embodiment of the connector with a contact lamellae basket.
• Fig. 2 shows an embodiment of the spring element.
• Fig. 3 shows a connector, wherein the spring element surrounds the contact lamella basket.
• Fig. 4a shows a first view of an embodiment with long recesses.
• Fig. 4b shows a second view of the embodiment with long recesses.

Detailed description of the figures

The variant of the connector explained below is designed as part of a socket. The connector may also be part of a connector. Although in the following, for better understanding, only embodiments are described for a socket, it is clear that only minor modifications are required in order to use them in a plug can.

Fig. 1 shows the main body 12 of a contact element of a connector. In the plug-in connection facing, the front portion of the connector is a contact lamellae basket 14. At the opposite end of the base body 12, the rear portion is an electrical / mechanical recording / contacting for an electrical Ladder, for example, a crimp 16 is provided. The main body 12 of the connector is in the in Fig. 1 embodiment shown executed as a stamped and bent part. The base body 12 consists of a tubular bent, conductive material. This material may be an unalloyed metal, for example copper. Furthermore, a separating slot 18 extends over the entire axial length of the main body 12.

The contact lamella basket 14 consists of a first and a second contact zone 20,21, which are electrically connected by an intermediate wall 22. This intermediate wall 22 extends over the entire circumference of the contact lamella basket 14 and is interrupted by the separating slot 18. In the contact zones 20,21 a plurality of contact blades 24 is arranged, which bear against the plug in the coupled state. At the in Fig. 1 In the illustrated embodiment, the cross-section of the contact blades 24 tapers towards the center, so that the distance between adjacent contact blades in the middle is greatest. Through this taper, the mechanical stress can be evenly distributed in the lamella. Since, starting from the center, the cross section of the lamella increases toward the intermediate wall 22, the heat loss can be better dissipated from the contact zones 20, 21.

In the middle, the contact blades, on the inside of the contact blade basket, an embossed contact point 26. This embossed contact point 26 is provided as a defined contact with the plug. In addition, embossed contacting points 26 may be provided on the outside of the contact lamellae basket. The advantages of such contacting points 26 are in the description of Fig. 3 set out in detail.

The transitions between base body 12, contact blades 24 of the second contact zone 20, intermediate wall 22, contact blades 24 of the first contact zones 21 are carried out seamlessly without a material transition. At the front end of the connector, the Kotaktlamellen 24 go into a front end ring 28, whose ring structure is interrupted by a plurality of gaps. This open ring structure favors the elastic deformation of the contact blades 24 of the first contact zone 21. This allows the contact blades 24 of the first contact zone 21 to optimally adapt to the geometry of the plug. Similarly, 12 recesses 30 are provided on the base body. These recesses 30 may be configured as slots, whereby the gaps between the contact blades 24 are extended into the base body 12 inside. Due to the elasticity of the contact blades 24, these act like springs. When the plug deforms the contact blades 24 elastically, there is a contacting the contact points 26 to the plug pressing force.

In the in Fig. 1 illustrated embodiment, the contact blades 24 of the first and second contact zones 20,21 are arranged offset in the circumferential direction. Additionally or alternatively, the contact blades 24 may also be aligned obliquely to the longitudinal direction of the connector. The staggered arrangement of the contact blades 24 potential differences can be compensated more effectively. Also, the electric current flowing in the contact blades 24 can be better distributed to the individual contact blades 24. In addition, the mechanical wear, or the abrasion can be reduced by an offset arrangement of the contact blades 24. As a result, the wear on a contact lamella basket 14 having two contact zones 20, 21 and an offset arrangement of the contact lamellae 24 is not greater than in the case of a contact lamella basket with only one contact zone.

The in Fig. 1 illustrated basic body 12 further has on its outer side a double-sided annular bead 32 and at least one radially oriented nub 34. In this way, the base body 12 can be easily and safely positioned and secured in a, not further illustrated, for example, two-part, insulating contact carrier system. In the assembled state, this contact carrier system encloses the main body 12 completely. Thus, the body 12 is protected from environmental influences and at the same time the live parts of the connector are isolated. In the contact carrier system, an annular groove is provided, with which the double-sided bead 32 can be supported. As a result, the base body 12 is protected against slipping along the longitudinal axis of the connector. Furthermore, recesses are provided in the contact carrier system of the connector for the at least one nub 34. As a result, a relative rotational movement between the base body 12 and the contact carrier system can be prevented. In addition, the at least one nub 34 can also be used for positioning during assembly, for example when crimping the connection lines.

The radially outwardly projecting bead 32 and / or the radially outwardly protruding nub 34 may also be formed radially inwardly. In this case, correspondingly shaped projections are formed in the contact carrier system. Mixed forms of projecting / recessed nubs / bead can be realized.

Fig. 2 shows a spring element 40, which is designed as a stamped and bent part. In this case, the spring element 40 consists of a tubular bent material. Since the spring element 40 is not intended to conduct current, the spring element 40 may be made of a material selected on the basis of its mechanical properties. It is advantageous to use a material with a large modulus of elasticity. So can for example Steel or stainless steel can be used. Since the modulus of elasticity of steel is greater than that of copper even at high temperatures, the contact force can be maintained at a high level.

The spring element 40 also has a separating slot 42. The embodiment shown consists of three circumferential rings 44,46,48, which are interrupted by the separating slot 42. Between these circumferential rings 44,46,48, separated by gaps, spring blades 50,52,54,56 arranged. The spring element 40 shown here has four spring blades 50,52,54,56. The spring action is achieved in that the spring blades 50,52,54,56 have a gap in the axial direction compared to the circumferential rings 44,46,48. This gap can be arranged diametrically opposite the separating slot. The resulting arch structure favors the elastic deformation of the individual spring blades 50,52,54,56. Thus, the contact force is applied to the first and the second contact zone 20,21 is the same size, it is expedient to execute the spring blades 50,52,54,56 similar. However, it is also possible to design the spring blades 50, 52, 54, 56 such that differences in the contacting forces of the individual contact zones 20, 21 can be compensated.

Fig. 3 shows an embodiment of the invention, in which the spring element 40 surrounds the contact lamella basket 14. In this case, the spring blades 50,52,54,56 are arranged such that each pair of spring blades 50,52,54,56 a contact zone 20,21 surrounds. In addition, the separating slot 18 of the main body 12 and the separating slot 42 of the spring element 40 may be arranged such that the two separating slots 18, 42 are diametrically opposed. In order to avoid a relative movement of the spring element 40 and of the main body 12, an anti-twist device, not shown in the figures, can be provided. This rotation can, for example, consist of a specially provided recess and an engaging in the recess lamella. In this case, the recess may be provided both on the base body 12 and on the spring element 40. The decisive factor is that recess and blade are not provided on the same component and are superimposed in the installed state. Since the spring blades 50,52,54,56 engage around the contact zones 20,21, they can apply a force acting transversely to the longitudinal direction of the connector on the contact zones 20,21 of the contact blade basket 14.

As already in the description of the Fig. 1 illustrated, 14 contacting points 26 may also be provided on the outside of the contact blade basket. These contacting points 26 form the interface between contact lamellae basket 14 and spring element 40. Since the spring element 40 rests only on the contacting points 26, the spring force specifically introduced into the contact blades 24. It is advantageous that the contacting points 26, seen in the axial direction, are arranged in the middle of the contact blades 24 and that the outer contacting points 26 and the inner contacting points 26 are exactly opposite.

Fig. 4a shows a first view of an embodiment with long recesses. Fig. 4b shows a second view of the embodiment with long recesses. The first view may be a front view and the second view may be a rear view of the connector.

The in the Fig. 4a and 4b illustrated embodiment differs essentially only by long recesses 31a, 31b of the in Fig. 1 illustrated embodiment. Therefore, a re-description of the structure of the connector is omitted. The long recesses 31a, 31b may be provided instead of a recess 30 in the base body 12. The long recesses 31a, 31b protrude further into the main body 12 than the recesses 30.

In the Fig. 4a The first long recess 31a is thus four times longer than a recess 30. It can be seen that the first long recess 31a is also shorter or longer can be. Thus, for example, it is also possible for the first long recess 31a to protrude twice as far into the main body 12, ie twice as long as a recess 30 Fig. 4a In the embodiment shown, the width of the first long recess 31a corresponds to the width of a recess 30. It can be seen that the first long recess 31a can also be wider or narrower without any problem.

The first long recess 31a extends in the longitudinal direction of the connector into the base body 12 inside. At one end, the first long recess 31a merges into the separating slot 18 of the main body 12. Thus, the first long recess 31 a can also be regarded as a widened part of the separating slot 18. At the other end, the first long recess 31a merges into a gap which separates two adjacent contact blades 24 from each other.

Also, the intermediate wall 22 is interrupted. In the in Fig. 4a illustrated embodiment, the interruption of the intermediate wall 22 is arranged obliquely to the longitudinal direction of the connector. The interruption of the intermediate wall 22 may be in the gap between two Pass over the contact blades 24, in which also the first long recess 31a merges. Thus, the interruption of the intermediate wall 22 may be arranged in extension of the first long recess 31a.

Fig. 4b shows a second long recess 31b. This corresponds in its length and width of the first long recess 31a. However, it is readily apparent that the second long recess 31b may also be wider, narrower, longer or shorter than the first long recess 31a. The second long recess 31b may be diametrically opposed to the first long recess 31a. Likewise, the second long recess 31b may also be arranged at a different angle to the first long recess 31a.

In the intermediate wall 22, a further interruption is provided. This interruption can be in the form and arrangement of in conjunction with Fig. 4a described interruption of the intermediate wall 22 correspond.

In the in the Fig. 4a and 4b illustrated embodiment, two long recesses 31a, 31b and in the intermediate wall 22 two interruptions are thus provided in the base body 12. It can be seen that the number of long recesses 31a, 31b and the interruptions of the intermediate wall 22 is only an example.

By the length of the long recesses 31a, 31b, the lever arm of the contact lamella basket 14 can be changed. Shortening the long recesses 31a, 31b shortens the lever arm and extending the long recesses 31a, 31b into the base body 12 extends the lever arm of the contact lamella basket 14. Since the length of the lever arm has a significant influence on the contact lamella 14 applied contact force, can the shape of the long recesses 31a, 31b, the contact force of the contact blade basket 14 are varied.

In general, the long recesses 31a, 31b cause a reduction in the contact force provided by the contact lamella basket 14. To compensate for this reduction, the force applied by the spring element 40 part of the contact force can be increased. Since the contact force can be applied more uniformly by the shape of the spring element 40 than by the contact lamellae basket, the long recesses 31a, 31b thus also effect that the contact force is applied more symmetrically.

Claims (13)

1. A plug connector with a main part (12), which
   comprises a contact blade skirt or basket (14) with at least one first and one second contact zone (20, 21), wherein
   the first and second contact zones (20, 21) are arranged one after the other in the longitudinal direction of the plug connector,
   the contact zones (20, 21) have a plurality of contact blades (24), and neighbouring contact blades (24) of one contact zone (20, 21) are separated from each another by a gap, with
   an intermediate wall (22) being provided between the first and the second contact zones (20, 21),
   the intermediate wall (22) forming a conductive connection both between the contact blades (24) of the first contact zone (21) and the contact blades (24) of the second contact zone (20) and between the individual contact blades (24) of the first contact zone (21) and the individual contact blades (24) of the second contact zone (20), characterized in that
   two long recesses (31a, 31b) are provided in the main part (12) which are arranged diametrically to each another.
2. The plug connector according to claim 1, wherein a spring element (40) is applying a force acting transversely to the longitudinal direction of the plug connectors to at least one of the contact zones (20, 21) of the contact blade skirt (14).
3. 2. The plug connector according to Claim 2, wherein the spring element (40) comprising at least one sprung blade (50, 52, 54, 56) for each contact zone (20, 21).
4. The plug connector according to claim 2 or 3, wherein the spring element (40) comprises an intermediate wall (22) between the sprung blades (50, 52, 54, 56) for the respective contact zones (20, 21), and/or wherein the spring element (40) encompasses the contact blade skirt (14) at least partially in the circumferential direction.
5. The plug connector according to one of the preceding claims, wherein the contact blades (24) of the first contact zone (21) are arranged in a staggered way relatively to the contact blades (24) of the second contact zone (20) in the circumferential direction, and/or
   wherein the contact blades (24) are arranged obliquely to the longitudinal axial of the plug connector.
6. The plug connector according to one of claims 2 to 5, wherein the contact blade skirt (14) comprises one or several surfaces of an unalloyed metal, for example, copper, as the contact area, or
   wherein the contact blade skirt (14) comprises one or several surfaces with a surface coating, for example, of tin or a tin alloy, as the contact area, and/or
   wherein the spring element (40) and the contact blade skirt (14) consist of different materials, and/or
   wherein the contact blade skirt (14) and the spring element (40) are stamped bent parts.
7. The plug connector according to one of the preceding claims, wherein the contact blades (24) have a tapering cross section along the longitudinal axis and/or at least one embossed contact making point (26) which faces in the radial direction.
8. The plug connector according to one of the preceding claims, wherein the contact blade skirt (14) towards the connector plug side opens into an end ring (28) which is interrupted by gaps.
9. The plug connector according to one of the preceding claims, wherein at least one recess is longer than the other recesses (30) and thus forms a long recess (31a, 31b).
10. The plug connector according to one of the preceding claims, wherein the intermediate wall (22) is interrupted at least once, preferably in an extension of at least one long recess (31a, 31b).
11. The plug connector according to one of claims 2 to 10, wherein a separation slot (42) of the spring elements (40) is arranged so as to be secured against rotation relative to a separation slot (18) of the contact blade skirt (14), with the two separation slots (18, 42) being diametrically opposed.
12. The plug connector according to one of the preceding claims, wherein the main part (12) comprises a double-sided bulb (32), and/or wherein the main part (12) comprises at least one knob (34), and/or wherein the main part (12) comprises a crimp connection, a screw connection, a screwless clamp connection, an insulation displacement connection, a flat cable plug connection, a winding connection, a press-fit connection or a weld connection for connecting the main part with a conductor.
13. The plug connector with several contact blade skirts (14) as defined in the preceding claims.

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