Classifications

• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
  • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
  • H01R4/10—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
  • H01R4/18—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
  • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
  • H01R13/02—Contact members
  • H01R13/03—Contact members characterised by the material, e.g. plating, or coating materials
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
  • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
  • H01R13/02—Contact members
  • H01R13/22—Contacts for co-operating by abutting
  • H01R13/24—Contacts for co-operating by abutting resilient; resiliently-mounted
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
  • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
  • H01R43/16—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for manufacturing contact members, e.g. by punching and by bending
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
  • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
  • H01R13/02—Contact members
  • H01R13/26—Pin or blade contacts for sliding co-operation on one side only
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
  • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
  • H01R4/58—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation characterised by the form or material of the contacting members
  • H01R4/62—Connections between conductors of different materials; Connections between or with aluminium or steel-core aluminium conductors
  • H01R4/625—Soldered or welded connections
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
  • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
  • H01R43/02—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for soldered or welded connections
  • H01R43/0207—Ultrasonic-, H.F.-, cold- or impact welding
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
  • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
  • H01R43/02—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for soldered or welded connections
  • H01R43/0221—Laser welding
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T29/00—Metal working
  • Y10T29/49—Method of mechanical manufacture
  • Y10T29/49002—Electrical device making
  • Y10T29/49117—Conductor or circuit manufacturing
  • Y10T29/49204—Contact or terminal manufacturing
  • Y10T29/49208—Contact or terminal manufacturing by assembling plural parts

Definitions

• the invention is based on a contact element for contacting an electrical contact point formed on a body, in particular a ceramic sensor element of a gas sensor, according to the preamble of claim 1.
• a known electrical contacting of a sensor element of a gas sensor or gas sensor with the electrical conductors of a connecting cable has at least one contact part or contact element, which presses non-positively on one of the connection-side portion of the sensor element formed contact points.
• the contact element has a sensor element- or contact-site-side portion which rests with spring action on the contact point, a connection-side portion which is connected to an electrical life of the connection cable, and an arc-shaped intermediate portion, which compensates for thermal and / or mechanical expansions and movements the contact element is used.
• the contact element consists of nickel or a nickel alloy and the contact point of a sintered platinum cermet with at least 95% platinum. Disclosure of the invention
• the contact element according to the invention with the features of claim 1 has the advantage that the contact element at delivery and installation z. B. in the gas sensor has functionally tailored areas that meet the requirements placed in operation. This reduces costs and improves and facilitates assembly. Thus, the use of expensive, warm solid material is limited to the contact-site-side element portion and the connection-side element section are made with lower strength, which in turn facilitates the crimping process when connecting an electrical conductor of a connection cable to the contact element and reduces the wear of the crimping tool.
• the integral contact element is a finished structural unit, so that complex processes for the connection of the individual element sections are omitted in later assembly of the contact element for producing an electrical contact, for example in a gas sensor, as in the sensor and wiring harness assembly.
• the contact-site-side element section of a heat-resistant alloy according to DIN 10269 advantageous refinements and improvements of the claim 1 contact element are possible.
• the contact-site-side element section of a heat-resistant alloy according to DIN 10269 advantageous refinements and improvements of the claim 1 contact element are possible.
• the contact-site-side element section of a heat-resistant alloy according to DIN 10269 advantageous refinements and improvements of the claim 1 contact element are possible.
• the contact-site-side element section of a heat-resistant alloy according to DIN 10269 The use of these heat-resistant and high heat nickel-base alloys ensures a high contact force with a long service life of the contact element.
• connection-side element section consists of a corrosion-resistant steel, the 1.43xx family according to DIN 10088, e.g. made of steel 1.4303.
• This material has a sufficiently high elongation at break and a low tendency to cold work. It is well deformable and is therefore very suitable for crimping in order to connect the connection-side element section with the electrical conductor of the connection cable and avoids excessive wear of the crimping tool, so that this achieves a long service life.
• this material is used in the solution-annealed state.
• the intermediate section consists of a work-hardened, corrosion-resistant steel of the 1.43xx family according to DIN 10088, for example of steel 1.4310.
• the extensibility of the intermediate portion so its axial spring characteristic set so that different thermal expansions of other components z. B. be compensated in a gas sensor.
• the contact element is connected via the electrical conductor of the connecting cable and an elastomer grommet to a metallic protective sleeve, which expands considerably more when the temperature rises than the sensor element.
• the work-hardened state which leads to a high yield strength of the intermediate section, also offers the advantage that the deformation characteristic remains in the elastic range and thus a cyclically occurring deformation is reversible.
• a cyclical deformation in the intermediate section which is triggered by vibrations of the contact element only partially received contact element, remains in the elastic range and is therefore reversible, so that the contact element - and thus the gas sensor - can be subjected to a higher vibration load.
• the method according to the invention with the features of claim 8 has the advantage that the individual element sections can be tailored to the corresponding functional requirements in a manufacturing-technically favorable manner.
• the partial integral design of the intermediate section with the contact-point-side element section and the connection-side ele- ment section reduces the number of items to be joined, without the adaptation of the intermediate section is significantly impaired to the functional requirement of balancing different thermal expansions.
• the joining and integral connection of the two items provides a later assembly, for. B. the gas sensor, a finished, integral contact element available, so that complex assembly processes, eg. B. during the sensor and wiring harness assembly of a gas sensor, omitted and the installation costs fall significantly.
• the inventive method with the features of claim 10 has the advantage that by the production of the multi-metal band of three different metal bands, the contact element by a simple
• the method according to the invention with the features of claim 9 has the advantage that the production of a bimetallic strip by a single cohesive connection along the abutting edges of the two material-different metal bands is possible by the merging of connection side end portion and intermediate portion with respect to the material selection and thereby further reduce the manufacturing costs.
• the material-identical design of the intermediate section with the connection-side element section somewhat adversely affects the optimum design of the axial spring characteristic curve of the intermediate section and the vibration resistance, both can be compensated by an adapted geometic design of the intermediate section.
• electron beam or laser welding can be used as in the production of the three-handed multifunctional belt.
• Follow-on composite tool are unchanged.
• FIG. 1 shows a perspective view of a contact element according to a first exemplary embodiment
• FIG. 2 shows a detail of a top view of a multi-metal band consisting of three metal bands for the stamping / bending process of the contact element in FIG. 1,
• FIG. 3 shows a perspective view of the contact element according to a second exemplary embodiment
• FIG. 4 a detail of a plan view of a bimetallic strip consisting of two metal strips for the punching / bending process of the contact element in FIG. 3,
• FIG. 5 shows a perspective top view of the contact element according to a third exemplary embodiment
• Figure 6 is a perspective view of individual pieces of the contact element in Figure 5 prior to their joining.
• the contact element to be seen in perspective view in FIG. 1 for contacting an electrical contact point formed on a body is used, for example, for contacting a planar contact point formed on the surface of a ceramic sensor element of a gas sensor.
• the contact element connects the contact point of the sensor element with an electrical conductor of a guided to the gas sensor connecting cable.
• a gas sensor with sensor element, connecting cable and contact element is described for example in the above-cited DE 196 38 208 C2.
• the contact element has three element sections, namely a contact-site-side element portion 1 1 for non-positive support on the contact point of the body, a connection-side element portion 12 for connection to an electrical connection conductor and the two element portion 11, 12 interconnecting intermediate portion to compensate for thermal expansions.
• a contact-site-side element portion 1 1 for non-positive support on the contact point of the body
• a connection-side element portion 12 for connection to an electrical connection conductor
• the flat contact point 14 formed on the body 10 on which the contact point-side element section 11 springs, and the electrical conductor 15, to which the connection-side element section 12 is electrically conductively connected, eg by crimping, are indicated schematically
• the contact-site-side element section 1 1, the connection-side element section 12 and the intermediate section 13 are made of different, cohesively bonded materials, each having adapted to the functionality of the respective element section material properties.
• the contact point-side element portion 1 1 made of a heat-resistant alloy according to DIN 10269.
• a heat-resistant or high temperature nickel-base alloy ensures at the high temperatures required of gas sensors high temperatures of about 400 ° C, a sufficiently high contact force over the life of the contact element.
• the connection-side element section 12 consists of a corrosion-resistant steel of the 1.43xx family according to DIN 10088, eg the corrosion-resistant steel 1.4303. Such a steel has a sufficiently high elongation at break and a low tendency to strain hardening, so that it is readily deformable during crimping to connect the connection-side element section 12 to the electrical connection conductor 15 and does not generate high tool wear of the crimping tool.
• the corrosion-resistant steel is used in a solution-annealed condition.
• the solution annealing brings the material back to its original state, which in addition to the uniform distribution of the alloy constituents, a decrease of solidification, so that the material is soft and therefore easy to shape.
• the intermediate section 13 consists of a work-hardened, corrosion-resistant steel of the 1.43xx family according to DIN 10088, eg the corrosion-resistant steel 1.4310. To ensure a linear characteristic of the extensibility of the intermediate portion 13 and the fatigue strength of the contact element, work hardening is performed. In addition to the choice of material, the intermediate section 13 is designed to improve its extensibility with a corresponding geometry, for example, with an apparent in Figure 1 sheet 131th
• FIG. 2 is a detail of one of the three metal strips 16, 17, 18 consisting of the aforementioned materials of the contact-site-side element section 11, the intermediate section 13 and the connection-side element section are first abutted with their longitudinal edges and joined together in a butt joint to form a multimetal strip 19 (FIG. 2).
• the cohesive connection can be produced by means of electron beam or laser welding.
• Figure 2 is a detail of one of the three metal strips 16, 17, 18 consisting of the aforementioned materials of the contact-site-side element section 11, the intermediate section 13 and the connection-side element section are first abutted with their longitudinal edges and joined together in a butt joint to form a multimetal strip 19 (FIG. 2).
• the cohesive connection can be produced by means of electron beam or laser welding.
• Figure 2 is a detail of one of the three
• Metal bands 16, 17, 18 existing multimetal band 19 in plan view darge provides.
• the two abutting edges, at which the three metal bands 16, 17, 18 are welded together, are marked 20 and 21, wherein the abutting edge 20 between the metal bands 16 and 18 and the abutting edge 21 between the metal bands 17, and 18 extends.
• From this multimetal band 19 now punched parts 22 are punched with extending transversely to the abutting edge longitudinal extent so that the contact-site-side end portion 11 of the metal strip 16, the intermediate portion 13 of the metal strip 18 and the connection-side element portion 12 emerges from the metal strip 17.
• a punched out punched part 22 and multimetal strip 19 are punched open at the top, while further punched parts 22 are shown figuratively in the multimetal strip 19 but have not yet been punched out. All punched parts 22 are still held together for manufacturing reasons via a running on the left edge of the multimetal band 19 punched tape strip 191, but later isolated.
• the connection side is formed by punching process at each stamped part 22 of the contact point-side element portion 1 1, the connection side
• the contact-site-side element section 11 and the connection-side element section 12 consist of different materially bonded materials, wherein in turn the material properties of the materials are adapted to the functionality of the element section 11 or 12.
• the contact-site-side element section 1 1 consists, like the same element section in FIG. 1, again of a heat-resistant alloy in accordance with DIN 10269.
• the connection-side element section 12 consists of a corrosion-resistant steel of the 1.43xx family according to DIN 10088 in the same way as described for FIG
• the intermediate section 13 consists of the same material as the connection-side element section 12, ie of a corrosion-resistant steel of the 1.43xx family according to DIN 10088.
• first two metal strips 16 and 23 consisting of the material of the contact-site-side element section 11 and the terminal-side element section 12 are juxtaposed with their longitudinal edges and joined together in a butt joint to form a bimetallic strip 24 (FIG ).
• the connection process can in turn be done by electron beam or laser welding.
• Figure 4 shows the bimetallic strip 24 thus produced in sections in plan view. The abutting edge in the bimetallic strip 24, along which the two metal strips 16 and 23 are welded together, is shown at 25 in FIG.
• a punched part 26 is punched with extending transversely to the abutting edge 25 longitudinal extent so that the contact-site-side element portion 11 of the metal strip 16 and the connection-side element section 12 emerges together with the intermediate portion 13 of the other metal strip 23.
• a stamped part 26 cut free from the bimetallic strip 24 is shown in FIG. 4 at the upper edge of the bimetallic strip 24. Further not punched punched parts 26 are shown in outline in the bimetallic strip 24 and are punched out individually or in groups depending on the design of the punch.
• the stamped parts 26 are separated.
• the contact-site-side element section 11 on the one hand and the connection-side element section 12 along with the intermediate section 13, on the other hand are formed on each stamped part 26, whereby the contact element fits into its in
• FIG. 3 shows the shape shown. Again, the punched parts 26 are in turn shown schematically and do not show the individual punching contours of the contact spring in Figure 3.
• the contact element according to a third exemplary embodiment illustrated in FIG. 5 in turn has the contact-site-side element section 11, the connection-side element section 12 and the intermediate section 13.
• the pad-side member portion 11 and the terminal-side member portion 12 form separate element pieces 27 and 28 ( Figure 6).
• the intermediate portion 13 is at least partially integral with at least one of the two element sections 1 1, 12, that is, consists of the same material as these.
• the two element pieces 27, 28 are connected in the region 29 of the intermediate portion 13 to a pre-assembled, integral unit cohesively together.
• Connection region 29 is indicated schematically in FIG. 5 by a dashed line.
• the element sections 11, 12 consist of different materials whose material properties are adapted to the functionality of the contact-site-side element section 11 or the connection-side element section 12.
• the contact-site-side element section 1 1 again consists of a heat-resistant alloy in accordance with DIN 10269, the connection-side element section 12 of a corrosion-resistant steel of the 1.43xx family according to DIN 10088.
• the intermediate section 13 consists partly of the same material as the contact-site-side element section 11 and partially made of the same material as the connection-side element section 12. These parts 13a and 13b of the intermediate section 13 are connected to one another in the region 29 in a material-locking manner, wherein the material connection is produced by an electron beam or laser welding process.
• the contact-site-side element section 11 on the one hand and the connection-side element section 12 on the other hand are each punched and bent together with a part 13a or 13b of the intermediate section 13 as separate element pieces 27, 28 (FIG. Thereafter, the two separate ele- piece pieces 27, 28 are joined, as indicated in Figure 6 by dashed lines, and in the region 29 of the intermediate portion 13 stoffschlüs- sig connected.

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• Engineering & Computer Science (AREA)
• Manufacturing & Machinery (AREA)
• Measuring Oxygen Concentration In Cells (AREA)
• Manufacturing Of Electrical Connectors (AREA)
• Manufacture Of Switches (AREA)
• Connection Of Plates (AREA)

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Citations (2)

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• 2011
  • 2011-03-16 DE DE102011005655A patent/DE102011005655A1/de active Pending
• 2012
  • 2012-02-09 CN CN201280013186.3A patent/CN103444002B/zh active Active
  • 2012-02-09 US US14/004,628 patent/US9627781B2/en active Active
  • 2012-02-09 KR KR1020137024248A patent/KR101962095B1/ko active IP Right Grant
  • 2012-02-09 RU RU2013145972A patent/RU2620361C2/ru active
  • 2012-02-09 WO PCT/EP2012/052198 patent/WO2012123195A1/de active Application Filing
  • 2012-02-09 EP EP12702565.8A patent/EP2686911A1/de active Pending
  • 2012-02-09 JP JP2013558347A patent/JP5800921B2/ja active Active
  • 2012-02-09 BR BR112013023608-6A patent/BR112013023608B1/pt active IP Right Grant

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