EP2800205B1 - Partially solid hollow pin - Google Patents
Partially solid hollow pin Download PDFInfo
- Publication number
- EP2800205B1 EP2800205B1 EP14166028.2A EP14166028A EP2800205B1 EP 2800205 B1 EP2800205 B1 EP 2800205B1 EP 14166028 A EP14166028 A EP 14166028A EP 2800205 B1 EP2800205 B1 EP 2800205B1
- Authority
- EP
- European Patent Office
- Prior art keywords
- plug pin
- axial length
- central area
- plug
- hollow
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Images
Classifications
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- 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
- H01R13/04—Pins or blades for co-operation with sockets
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
- B21C23/00—Extruding metal; Impact extrusion
- B21C23/21—Presses specially adapted for extruding metal
- B21C23/218—Indirect extrusion presses
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21K—MAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
- B21K21/00—Making hollow articles not covered by a single preceding sub-group
- B21K21/08—Shaping hollow articles with different cross-section in longitudinal direction, e.g. nozzles, spark-plugs
-
- 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
- H01R4/183—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 for cylindrical elongated bodies, e.g. cables having circular cross-section
-
- 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
- H01R13/40—Securing contact members in or to a base or case; Insulating of contact members
- H01R13/405—Securing in non-demountable manner, e.g. moulding, riveting
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R2103/00—Two poles
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R24/00—Two-part coupling devices, or either of their cooperating parts, characterised by their overall structure
- H01R24/20—Coupling parts carrying sockets, clips or analogous contacts and secured only to wire or cable
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R24/00—Two-part coupling devices, or either of their cooperating parts, characterised by their overall structure
- H01R24/28—Coupling parts carrying pins, blades or analogous contacts and secured only to wire or cable
-
- 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
- H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
- H01R43/20—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for assembling or disassembling contact members with insulating base, case or sleeve
- H01R43/24—Assembling by moulding on contact members
Definitions
- the invention relates to a plug pin for producing an electrical contact between a power cord of a plug cable and a socket contact, wherein the plug pin has a connection end for electrical connection to the Netzan gleichlitze and leading from the connection end to a plug-side contact end electrically conductive central region, wherein the connecting end as a hollow crimp end is formed, and wherein the connection end and at least a part of the socket-side contact end are formed hollow by deep drawing or in extrusion molding.
- Such at least partially hollow connector pins are described for example in WO 2009/021491 A2 .
- DE 10 2007 062 500 A1 as in DE 196 27 335 C1 , in EP 0 128 990 A1 , in GB 2 083 716 A or in DE 101 51 990 A1 ,
- An extruded hollow pin is already in DE 11 18 303 B , a extruded push pin made of solid material is in DE 102 03 171 A1 , a extruded hollow connector in DE 31 23 850 C2 or for example in US 2006/0102375 A1 , a connector bridge with extruded hollow plug pin in DE 20 2007 017 752 U1 and a pin with connection hole at the connection end in DE 86 33 492 U1 disclosed.
- jumper bridges are installed in large quantities in the production of device connectors. Since relatively small price differences already have a significant impact on competitiveness in the fiercely contested market, developments to reduce costs or material in this technical field are particularly important.
- a pin is described, which is formed from a rolled sheet metal strip.
- the interior of the connector pin can also be filled with plastic. In this way, only round pin shapes can be made.
- Object of the present invention is in contrast to improve a generic pin with the technical features described above by simple technical means inexpensive and inexpensive and without the use of additional parts to the extent that continue in the production of considerable material and thus in particular weight and cost can be saved, the plug pin but in its central region, where it is installed in the plastic base plate of a jumper is compared to the known, especially extruded hollow pins considerably mechanically reinforced and beyond the pouring of the connector pin in the base plate of the connector bridge the Danger of penetrating into the cavities of the connector pin liquid plastic or moisture due to the prevailing ambient atmosphere with absolute certainty is avoided.
- connection end and plug-side contact end ensures that when pouring the connector pin according to the invention in the plastic base plate of a connector bridge under no circumstances liquid plastic or Moisture over the connection end with the - of course hollow - crimping and the central area in the - again hollow - plug socket side contact end passes.
- a mass of continuous cavity in the context of the invention, inter alia, a - about after a radial compression of a hollow blank - closed-fitting radially innermost material area can be understood. In this case, even tiny micro-gaps in a size range below 0.1 mm are permissible, without thereby forming a continuous hollow space between the connection end and the socket-side contact end, which in any case can be excluded.
- the central region may have an axial length of 3mm to 8mm, preferably an axial length of about 5mm and solid on an axial length of 1mm to 3mm, preferably an axial length of about 2mm be formed without continuous cavity between the connecting end and steckdosen sum contact end.
- the central region has an axial length of 10% to 20%, preferably an axial length of about 15% of the total axial length of the connector pin and an axial length of 5% to 10%, preferably formed on an axial length of about 7% of the total axial length of the connector pin solid without continuous cavity between the connecting end and steckdosen sum contact end.
- pin closure is a defined hole relationship or cavity depth and a defined cavity end on the lying for further processing during crimping of the individual strands of the core cross-section side.
- Another group of embodiments is characterized in that the central region is helically wound around the longitudinal axis of the connector pin, whereby the natural material flow during extrusion is even better Account is taken. The mechanical strength is better pronounced. The pin hole to the cavity is closed.
- the central region is conically pressed into the plug pin, wherein preferably the conically shaped central region tapers from the connecting end to the socket-side contact end. This ensures that the pin receives a further improved torsional and expressive power protection.
- the hollow cone produced has its largest opening cross-section in the direction of the power cord of the plug cable to be inserted into the crimp end 2a, the insertion of the strand is facilitated by a guiding action.
- the middle region is pressed into the plug pin in a crowned manner. This also allows the area to be closed to the pen.
- FIG. 1 Further embodiments of the connector pin according to the invention can provide that the central region has a plurality of radial cross-sectional constrictions in axial sequence along the longitudinal axis of the connector pin. In this way it is possible that in a good relation between force and result of the pin is closed at the bottom of the hole. This reduces tool wear during production.
- the socket-side contact end has an axial length of 10mm to 50mm, preferably of about 20mm and a continuous cavity on an axial length of 5mm to 48mm, preferably on an axial length of about 18mm.
- socket-side contact end has an axial length of 50% to 80%, preferably has an axial length of about 2/3 of the total axial length of the connector pin and a continuous cavity on an axial length of 35% to 75%, preferably on an axial length of about 60% of the axial total length of the connector pin.
- a plug bridge with at least one plug pin of the type described above according to the invention which is characterized in that it comprises a base plate made of thermoplastic material, preferably flame retardant plastic material, in which at least one plug pin is cast, wherein the thickness the base plate substantially corresponds to the axial length of the central region of the at least one connector pin.
- embodiments of this connector bridge are preferred, which are characterized in that an electrical fuse is provided against excessive current flow, which is required by law in many countries.
- a method for producing a connector pin of the type described above with a connection end for electrical connection to a power cord and leading from the connection end to a plug-side contact end electrically conductive central region which is characterized in that in a first manufacturing step (a) from a hollow blank is produced by forming, in particular by deep drawing or extrusion molding, that in a second production step (b) the initially hollow cross section in the central region of the hollow blank by concentric pressing, rolling or tapering radially to the axis of the hollow blank in such a way is compressed, that the central region of the compressed blank plastic fluid-tight and at least partially solid without continuous cavity between the connecting end and steckdosen usedem Contact end is formed, and that then in a third manufacturing step (c), the hollow connection end of the compressed blank is formed by rolling, embossing or cutting as a crimp end, so that a plug pin for establishing an electrical contact between a power cord of a plug cable and a socket contact is formed.
- modified plug pins can be inexpensively produced in the required, very high number of pieces and in economic cycle times.
- the forming tool used in the first production step (a) for producing the hollow blank from the solid metallic blank with a punch end portion still at the axial height of the connection end is seated in the cavity of the hollow blank, while the hollow blank is subjected to concentric pressing, rolling or tapering at the axial height of the later central region of the resulting compressed blank radially to the axis.
- the punch end of the forming tool used thus acts as a counter-bearing during compression of the central region, resulting in an additional - highly desirable - material hardening and a particularly well-defined geometric shape of the massive bottleneck (s) contributes.
- FIGS. 1a to 4c show embodiments of a connector pin 1 according to the invention ; 1.1; 1.2; 1.3; 1.4 for making electrical contact between a power cord of a patch cord and a socket contact, wherein the pin 1; 1.1; 1.2; 1.3; 1.4 a longitudinal axis a, a connection end 2 for electrical connection to the power cord and a leading from the connection end 2 to a socket-side contact end 3 electrically conductive central region 4; 4.1; 4.2; 4.3; 4.4 , and wherein the connection end 2 is formed as a crimp end 2a .
- the plug pin 1 according to the invention; 1.1; 1.2; 1.3; 1.4 is characterized in that the connecting end 2 and at least a part of the socket-side contact end 3 hollow by deep drawing or in extrusion molding, the central region 4; 4.1; 4.2; 4.3; 4.4, however, plastic fluid-tight and at least partially massive are formed without continuous cavity between the connecting end 2 and plug-side contact end 3.
- FIG. 3 illustrates an embodiment of the plug pin 1.1 according to the invention in a schematic longitudinal section containing the longitudinal axis.
- the middle section 4.1 is compressed in all directions in a direction radial to the longitudinal axis a from all sides to a solid, plastic fluid-tight barrier between the connection end 2 and the socket side Training contact 3.
- Fig. 1 b shows the pin 1.1 Fig. 1 a in a side view. Indicated in both figures, respectively, the installation situation of the connector pin 1.1 in the base plate 5 a - for clarity in the drawing otherwise not shown - connector bridge.
- FIG. 2a is again shown in longitudinal section the structure of a further embodiment of the connector pin 1.2 according to the invention, which has a wound around the longitudinal axis of the connector pin around 1.2 center area 4.2, as in the side view of Fig. 2b is clearly visible.
- Fig. 2c shows in horizontal section through the plane AA of Fig. 2b the cross-section of the central area 4.2 at its narrowest point.
- Fig. 3a also shows a schematic longitudinal section of an embodiment of the plug pin 1.3 according to the invention with a central region 4.3, which is conically pressed into the plug pin 1.3.
- the conically shaped central region 4.3 tapers from the connection end 2 to the socket-side contact end 3 in order to facilitate the insertion of the power cord of a plug cable - both of which are not shown in the drawing.
- the side view of the pin 1.3 in Fig. 3b as well as in Fig. 3c shown cross section of the central region 4.3 Fig. 3b illustrate the fluid-tight barrier produced by the conical shape of the central region 4.3 between the connection end 2 and the socket-side contact end 3 of the connector pin 1.3.
- Fig. 4a shows a longitudinal section of an embodiment of the connector pin 1.4 according to the invention, in which the central region 4.4 is pressed into the connector pin 1.4 spherically.
- Fig. 4b provides the to the embodiment of Fig. 4a associated side view and Fig. 4c again the cross-section of the central area 4.4 Fig. 4b ,
- a second production step (b) the initially hollow cross-section in the central region 4 of the hollow blank 1 "is compressed by concentric pressing, rolling or tapering radially to the longitudinal axis of the hollow blank 1" such that the central region 4 of the compressed blank 1 "'plastic fluid-tight and is at least partially solid without continuous cavity between the connection end 2 and steckdosen wornem contact end 3 is formed.
- a plug pin 1 according to the invention for establishing an electrical contact between a power cord of a Plug cable and a socket contact arises.
- the forming tool used in the first production step (a) for producing the hollow blank 1 "from the solid metallic blank 1 'still has a punch end section at the axial height of the connecting end 2 in the cavity the hollow blank 1 ", while the hollow blank 1" is subjected to a concentric pressing, rolling or tapering at the axial height of the later central region 4 of the resulting compressed blank 1 '"radially to the axis.
- the stamp end of the tool can then act as an abutment in the radial deformation and solidification of the central region 4 taking place in the third production step (c).
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Connector Housings Or Holding Contact Members (AREA)
Description
Die Erfindung betrifft einen Steckerstift zur Herstellung eines elektrischen Kontaktes zwischen einer Netzanschlusslitze eines Steckerkabels und einem Steckdosenkontakt, wobei der Steckerstift ein Verbindungsende zur elektrischen Verbindung mit der Netzanschlusslitze und einen vom Verbindungsende zu einem steckdosenseitigen Kontaktende führenden elektrisch leitenden Mittelbereich aufweist, wobei das Verbindungsende als hohles Crimpende ausgebildet ist, und wobei das Verbindungsende und zumindest ein Teil des steckdosenseitigen Kontaktendes hohl durch Tiefziehen oder in Fließpressumformung ausgebildet sind.The invention relates to a plug pin for producing an electrical contact between a power cord of a plug cable and a socket contact, wherein the plug pin has a connection end for electrical connection to the Netzanschlusslitze and leading from the connection end to a plug-side contact end electrically conductive central region, wherein the connecting end as a hollow crimp end is formed, and wherein the connection end and at least a part of the socket-side contact end are formed hollow by deep drawing or in extrusion molding.
Derartige zumindest teilweise hohle Steckerstifte sind beispielsweise beschrieben in
Die Grundidee eines solchen Hohlstifts ist aber auch schon aus
Ein fließgepresster hohler Steckerstift ist bereits in
Steckerbrücken, wie sie etwa in
Diese und ähnliche Steckerbrücken werden bei der Produktion von Gerätesteckern in großen Stückzahlen verbaut. Da sich auf dem stark umkämpften Markt bereits relativ kleine Preisunterschiede erheblich auf die Konkurrenzfähigkeit auswirken, haben Entwicklungen zur Einsparung von Kosten bzw. Material in diesem technischen Gebiet einen besonders großen Stellenwert.These and similar jumper bridges are installed in large quantities in the production of device connectors. Since relatively small price differences already have a significant impact on competitiveness in the fiercely contested market, developments to reduce costs or material in this technical field are particularly important.
Ausgehend von normgerechten Konstruktionen, wie sie in
In
In der
Aber auch die eingangs diskutierten fließgepressten hohlen Steckerstifte, wie sie etwa in
- So muss etwa beim Vercrimpen der Netzanschlusslitze des Steckerkabels im Verbindungsende akribisch darauf geachtet werden, dass die Vercrimpung auf jeden Fall kunststofffluiddicht ausgeführt wird, so dass ein flüssigkeitsdichter Pfropfen den Hohlkanal des Steckerstifts abschließt. Sonst ist nämlich beim Vergießen des Steckerstifts in die aus thermoplastischem Material aufgebaute Grundplatte der Steckerbrücke ein Eindringen des -zu diesem Zeitpunkt flüssigen- Kunststoffs in das Innere des Hohlstifts zu befürchten, was unbedingt vermieden werden muss. Leider ist dies bei einem niederpreisigen Massenartikel wie dem in Frage stehenden Steckerstift in einem industriellen Maßstab, zumindest ohne erhebliche zusätzliche und damit selbstverständlich kostentreibende Qualitätssicherungsmaßnahmen, nicht zu garantieren.
- For example, when crimping the power cord of the plug cable in the connecting end, care must be taken to ensure that the crimping is carried out in any case in a plastic fluid-tight manner so that a liquid-tight plug closes off the hollow channel of the plug pin. Otherwise, namely when pouring the pin into the built-up of thermoplastic material base plate of the connector bridge penetration of -zu-this time liquid plastic to be feared in the interior of the hollow pin, which must be avoided at all costs. Unfortunately, this is in a low-priced mass-produced items such as the relevant pin in an industrial scale, at least without significant additional and thus of course cost-driving quality assurance measures can not be guaranteed.
Ein weiterer erheblicher Nachteil des Steckerstifts nach diesem Stand der Technik liegt darin, dass er gerade in dem mechanisch besonders stark beanspruchten Mittelbereich aufgrund der vorgeschlagenen hohlen Ausbildung des Mittelbereichs und der deshalb relativ dünnen Wandstärke nicht mit der erforderlichen Sicherheit den vorgeschriebenen Festigkeitsanforderungen genügt.Another significant disadvantage of the connector pin according to this prior art is that it does not meet the required strength requirements, especially in the mechanically particularly heavily loaded central region due to the proposed hollow design of the central region and therefore relatively thin wall thickness.
Zwar wird im oben diskutierten Stand der Technik die - zusätzliche - Ausbildung eines Torsions- und/oder Ausziehschutzes durch Vorsehen einer Verdickung am Außenumfang des Mittelbereichs, wo der Steckerstift im Steckerbrücken-Grundkörper sitzen soll, angeregt. Diese Verdickung soll dann auch eine Profilierung durch Rändelung, Eintiefung und/oder Einprägung erhalten und verstärkt natürlich lokal den hohlen Mittelbereich, da dieser durch die Verdickung eine größere Wandstärke erhält. Allerdings ist dies offensichtlich wiederum nur durch erhöhten Materialeinsatz beim Steckerstift "erkauft", was ja dem erklärten Ziel dieses Standes der Technik diametral zuwider läuft. Außerdem wirken sich die dadurch notwendig werdenden zusätzlichen Fertigungsschritte zweifelsohne ungünstig auf die Herstellungskosten des Steckerstifts aus.Although in the above-discussed prior art, the - additional - training a torsion and / or Ausziehschutzes by providing a thickening on the outer circumference of the central region, where the pin is to sit in the plug-bridge body, excited. This thickening should then also be profiled by knurling, recessing and / or embossing and, of course, locally reinforces the hollow central area, since this thickening gives it a greater wall thickness. However, this is obviously again only by increased use of materials in the pin "bought", which is diametrically contrary to the declared goal of this state of the art. In addition, the additional manufacturing steps that become necessary as a result undoubtedly have an unfavorable effect on the production costs of the connector pin.
Aufgabe der vorliegenden Erfindung ist es demgegenüber, einen gattungsgemäßen Steckerstift mit den eingangs beschriebenen technischen Merkmalen durch möglichst einfache technische Mitteln unaufwändig und kostengünstig sowie ohne Einsatz zusätzlicher Teile dahin gehend zu verbessern, dass weiterhin bei der Herstellung in erheblichem Maße Material und damit insbesondere Gewicht und Kosten eingespart werden können, wobei der Steckerstift aber in seinem Mittelbereich, wo er in die Kunststoff-Grundplatte einer Steckerbrücke eingebaut ist/wird, gegenüber den bekannten, insbesondere fließgepressten Hohlstiften erheblich mechanisch verstärkt ist und darüber hinaus beim Eingießen des Steckerstifts in die Grundplatte der Steckerbrücke die Gefahr von in die Hohlräume des Steckerstifts eindringendem flüssigem Kunststoff oder Feuchtigkeit aufgrund der vorherrschenden Umgebungsatmosphäre mit absoluter Sicherheit vermieden wird.Object of the present invention is in contrast to improve a generic pin with the technical features described above by simple technical means inexpensive and inexpensive and without the use of additional parts to the extent that continue in the production of considerable material and thus in particular weight and cost can be saved, the plug pin but in its central region, where it is installed in the plastic base plate of a jumper is compared to the known, especially extruded hollow pins considerably mechanically reinforced and beyond the pouring of the connector pin in the base plate of the connector bridge the Danger of penetrating into the cavities of the connector pin liquid plastic or moisture due to the prevailing ambient atmosphere with absolute certainty is avoided.
Diese - technisch recht anspruchsvolle - Aufgabe wird erfindungsgemäß auf ebenso verblüffend einfache wie überraschend wirkungsvolle Weise dadurch gelöst, dass das Verbindungsende und zumindest ein Teil des steckdosenseitigen Kontaktendes hohl durch Umformung, insbesondere durch Tiefziehen oder in Fließpressumformung, der Mittelbereich hingegen durch konzentrisches Verpressen, Rollieren oder Verjüngen von Wandteilen des Mittelbereichs radial zur Achse kunststofffluiddicht und zumindest abschnittsweise massiv ohne durchgängigen Hohlraum zwischen Verbindungsende und steckdosenseitigem Kontaktende ausgebildet sind.This - technically quite sophisticated - task is inventively solved in equally amazingly simple and surprisingly effective manner that the connecting end and at least a portion of the socket-side contact end hollow by forming, in particular by deep drawing or extrusion molding, the central area, however, by concentric pressing, rolling or Rejuvenating wall parts of the central region radially to the axis plastic fluid-tight and at least partially solid without continuous cavity between the connecting end and steckdosenseitigem contact end are formed.
Die vorliegende Erfindung schlägt also das genaue Gegenteil von dem vor, was der eingangs zitierte Stand der Technik nach den Druckschriften
- Anstelle eines hohl gestalteten Mittelbereichs verlangt die erfindungsgemäße Lehre einen durch konzentrisches Verpressen, Rollieren oder Verjüngen von Wandteilen des Mittelbereichs radial zur Achse zumindest teilweise massiven, kunststofffluiddicht gestalteten Mittelbereich des Steckerstifts, bei welchem im Gegensatz zu dem etwa in
WO 2009/021491 A2
- Instead of a hollow-shaped central region, the teaching of the invention requires by concentric pressing, rolling or tapering of wall portions of the central region radially to the axis at least partially solid, plastic fluid-tight designed center region of the connector pin, wherein in contrast to the approximately in
WO 2009/021491 A2
Dennoch gelingt es aufgrund der erfindungsgemäßen Lehre, die in dem oben genannten Stand der Technik aufgeführten wesentlichen Vorteile des dortigen Hohlstiftes, nämlich eine erhebliche Einsparung an Gewicht und Material ohne größere Einbuße an Festigkeit vollständig beizubehalten, wobei die Materialfestigkeit an einer besonders wichtigen und empfindlichen Stelle durch die erfindungsgemäß vorgeschriebene massive Ausführung des Steckerstifts in seinem Mittelbereich sogar noch wesentlich erhöht wird.Nevertheless, it is possible due to the teachings of the invention, the substantial advantages of the local hollow pin listed in the above-mentioned prior art, namely a considerable saving in weight and material without major loss of strength to completely maintain the material strength at a particularly important and sensitive point the inventively prescribed massive version of the connector pin is even significantly increased in its central region.
Zudem wird dadurch, dass kein durchgängiger Hohlraum zwischen Verbindungsende und steckdosenseitigem Kontaktende ausgebildet wird, sichergestellt, dass beim Eingießen des erfindungsgemäßen Steckerstifts in die Kunststoff-Grundplatte einer Steckerbrücke keinesfalls flüssiger Kunststoff oder Feuchtigkeit über das Verbindungsende mit dem - selbstverständlich hohlen - Crimpende und den Mittelbereich in das - wiederum hohle - steckdosenseitige Kontaktende gelangt. In diesem Zusammenhang sei darauf hingewiesen, dass unter einem "massiven Mittelbereich ohne durchgängigen Hohlraum" im erfindungsgemäßen Sinne unter anderem auch ein - etwa nach einem radialen Verpressen eines hohlen Rohlings - geschlossen anliegender radial innerster Materialbereich verstanden werden kann. In diesem Fall sind auch winzige Mikrospalte in einem Größenbereich unterhalb von 0,1 mm zulässig, ohne dass dadurch ein - erfindungsgemäß jedenfalls auszuschließender - durchgängiger Hohlraum zwischen Verbindungsende und steckdosenseitigem Kontaktende ausgebildet würde.In addition, the fact that no continuous cavity between the connection end and plug-side contact end is formed, ensures that when pouring the connector pin according to the invention in the plastic base plate of a connector bridge under no circumstances liquid plastic or Moisture over the connection end with the - of course hollow - crimping and the central area in the - again hollow - plug socket side contact end passes. In this context, it should be noted that under a "massive central area without continuous cavity" in the context of the invention, inter alia, a - about after a radial compression of a hollow blank - closed-fitting radially innermost material area can be understood. In this case, even tiny micro-gaps in a size range below 0.1 mm are permissible, without thereby forming a continuous hollow space between the connection end and the socket-side contact end, which in any case can be excluded.
Ein weiterer praktischer Vorteil des erfindungsgemäß ausgestalteten Steckerstifts liegt darin, dass durch die - zumindest teilmassive - Ausbildung des Mittelbereichs ein definierter Anschlag beim Einführen der Netzanschlusslitze in das hohle Crimpende des Steckers geschaffen wird. Damit wird ein Durchstecken der Litze bis zum steckdosenseitigen Steckergrund - wie es bei dem Hohlstift nach dem oben diskutierten gattungsbildenden Stand der Technik praktisch unausweichlich ist - sicher vermieden. Dies wiederum erhöht - ohne weitere Zusatzmaßnahmen - die Prozess-Sicherheit bei der Herstellung ganz erheblich, was wiederum den wirtschaftlichen Wert dieses in riesigen Stückzahlen hergestellten Massenartikels entscheidend anhebt.Another practical advantage of the inventively designed connector pin is that by the - at least partially massive - training of the central region a defined stop when inserting the power cord is created in the hollow crimp end of the plug. Thus, a passage of the wire to the socket-side plug base - as is virtually unavoidable in the hollow pin according to the generic art discussed above - safely avoided. This, in turn, significantly increases process safety in manufacturing without any additional measures, which in turn dramatically increases the economic value of this mass-produced mass-produced article.
Schließlich besteht bei dem erfindungsgemäßen Steckerstift auch der nicht zu unterschätzende Vorteil, dass der "Innenraum" des steckdosenseitigen hohlen Kontaktendes des nach der erfindungsgemäßen Lehre teilmassiv hergestellten Hohlstifts, der in der Praxis ja den "Löwenanteil" der axialen Länge des Stiftes einnehmen wird, bereits vor dem Fertigungsschritt des Crimpens sicher geschützt ist gegen Oxidation sowie gegen Korrosion durch eindringende Feuchtigkeit.Finally, in the connector pin according to the invention also the not to be underestimated advantage that the "interior" of the socket-side hollow contact end of the teaching of the invention partially hollow post, which in practice will take the "lion's share" of the axial length of the pin, already before the manufacturing step of crimping is safely protected against oxidation as well as against corrosion by penetrating moisture.
Bei Anwendung der erfindungsgemäßen Lehre eines im Mittelbereich massiven Steckerstifts werden daher nicht nur sämtliche Vorteile des fließgepressten Hohlstifts gemäß dem eingangs genannten Stand der Technik, wie er etwa in der
Gegenüber dem bekannten "einfachen Hohlstift" stellt also der erfindungsgemäße "teil-massive Hohlstift" so etwas wie eine "Quadratur des Kreises" dar.Compared to the well-known "simple hollow pin" thus represents the invention "partial-solid hollow pin" something like a "quadrature of the circle" is.
Bei Ausführungsformen des erfindungsgemäßen Steckerstifts in handelsüblichen Größen mit besonderer Marktbedeutung kann der Mittelbereich eine axiale Länge von 3mm bis 8mm, vorzugsweise eine axiale Länge von etwa 5mm aufweisen und auf einer axialen Länge von 1 mm bis 3mm, vorzugsweise auf einer axialen Länge von etwa 2mm massiv ohne durchgängigen Hohlraum zwischen Verbindungsende und steckdosenseitigem Kontaktende ausgebildet sein.In embodiments of the connector pin according to the invention in commercially available sizes with particular market significance, the central region may have an axial length of 3mm to 8mm, preferably an axial length of about 5mm and solid on an axial length of 1mm to 3mm, preferably an axial length of about 2mm be formed without continuous cavity between the connecting end and steckdosenseitigem contact end.
Besonders bevorzugte Ausführungsformen des erfindungsgemäßen Steckerstifts sind dadurch gekennzeichnet, dass der Mittelbereich eine axiale Länge von 10% bis 20%, vorzugsweise eine axiale Länge von etwa 15% der axialen Gesamtlänge des Steckerstifts aufweist und auf einer axialen Länge von 5% bis 10%, vorzugsweise auf einer axialen Länge von etwa 7% der axialen Gesamtlänge des Steckerstifts massiv ohne durchgängigen Hohlraum zwischen Verbindungsende und steckdosenseitigem Kontaktende ausgebildet ist. Mit diesen geometrischen Verhältnissen treten die oben genannten Hauptvorteile des erfindungsgemäßen Steckerstifts gegenüber dem Stand der Technik, nämlich eine erhebliche Gewichts- und Materialeinsparung bei gleichzeitig wesentlich erhöhter mechanischer Festigkeit im Mittelbereich am deutlichsten zutage.Particularly preferred embodiments of the connector pin according to the invention are characterized in that the central region has an axial length of 10% to 20%, preferably an axial length of about 15% of the total axial length of the connector pin and an axial length of 5% to 10%, preferably formed on an axial length of about 7% of the total axial length of the connector pin solid without continuous cavity between the connecting end and steckdosenseitigem contact end. With these geometrical conditions, the above-mentioned main advantages of the plug pin according to the invention over the prior art, namely a significant weight and material savings at the same time significantly increased mechanical strength in the central region are most evident.
Ganz besonders vorteilhaft ist auch eine Klasse von Ausführungsformen, bei denen der Mittelbereich über die axiale Länge desjenigen Abschnitts beziehungsweise derjenigen Abschnitte, die massiv ohne durchgängigen Hohlraum ausgeführt sind, an seinem Außenumfang mindestens eine Querschnittsverengung auf 25% bis 75%, vorzugsweise auf etwa 2/3 des Querschnitts der übrigen Abschnitte des Mittelbereichs aufweist. Ein wesentlicher zusätzlicher Vorteil dieser Ausgestaltung des erfindungsgemäßen Steckerstifts liegt auch darin, dass sein Mittelbereich aufgrund der "Einschnürung um die Taille" eine Retention aufweist, die im Sinne eines Torsions- und/oder Ausziehschutzes wirkt und etwa einem Herausziehen des Steckerstifts nach dem Eingießen in die Kunststoff-Grundplatte einer Steckerbrücke aus dem noch weichen Kunststoff erheblichen Widerstand entgegensetzt, so dass damit die Fertigungssicherheit wesentlich erhöht und der anfallende Ausschuss auf ein Minimum reduziert werden können. Gerade wegen der an dieser Stelle sehr hohen mechanischen Beanspruchung des Steckerstifts wirkt sich hier der besonders stabile - weil erfindungsgemäß massive - Mittelbereich äußerst positiv aus.Also particularly advantageous is a class of embodiments in which the central region over the axial length of that section or those sections which are designed solid without a continuous cavity, at least one at its outer periphery Has cross-sectional constriction to 25% to 75%, preferably about 2/3 of the cross section of the remaining portions of the central region. A significant additional advantage of this embodiment of the connector pin according to the invention lies in the fact that its central region due to the "constriction around the waist" has a retention that acts in the sense of torsion and / or Ausziehschutzes and about a withdrawal of the pin after pouring into the Plastic base plate of a connector bridge from the still soft plastic opposes significant resistance, so that significantly increases the manufacturing security and the resulting rejects can be reduced to a minimum. Precisely because of the very high mechanical stress of the plug pin at this point, the particularly stable central area, which is massive in accordance with the invention, has an extremely positive effect here.
Eine Gruppe von Ausführungsformen des erfindungsgemäßen Steckerstifts zeichnen sich dadurch aus, dass der Mittelbereich in radialer Richtung quer zur Längsachse des Steckerstifts verpresst ist. Dies hat den Vorteil, dass sich der Steckerstift noch besser in axialer Richtung im Kunststofftragkörper fixiert, was für die Weiterverarbeitung beim PVC Umspritzen sowie für eine Prozesssicherheit sehr wichtig ist. Weiterhin wird die Stiftbohrung zum Hohlraum schon an der Steckerbrücke vor dem Vercrimpen verschlossen. Damit ist keine eindringende Feuchtigkeit möglich, die durch den Crimpprozess eingeschlossen werden könnte, wie dies im Stand der Technik oftmals der Fall ist.A group of embodiments of the connector pin according to the invention are characterized in that the central region is pressed in the radial direction transversely to the longitudinal axis of the connector pin. This has the advantage that the plug pin fixes even better in the axial direction in the plastic support body, which is very important for further processing in PVC overmolding and for process safety. Furthermore, the pin hole is closed to the cavity already at the connector bridge before crimping. Thus, no penetrating moisture is possible, which could be trapped by the crimping process, as is often the case in the prior art.
Ein weiterer Vorteil aufgrund des Stiftverschlusses ist eine definierte Bohrungsbeziehungsweise Hohlraumtiefe sowie ein definiertes Hohlraumende auf der für die Weiterverarbeitung beim Vercrimpen der Einzellitzen des Aderquerschnittes liegenden Seite.Another advantage due to the pin closure is a defined hole relationship or cavity depth and a defined cavity end on the lying for further processing during crimping of the individual strands of the core cross-section side.
Eine weitere Gruppe von Ausführungsformen ist dadurch gekennzeichnet, dass der Mittelbereich wendelförmig um die Längsachse des Steckerstifts verwunden ist, wodurch dem natürlichen Materialfluss beim Fließpressen noch besser Rechnung getragen wird. Die mechanische Festigkeit wird besser ausgeprägt. Die Stiftbohrung zum Hohlraum ist verschlossen.Another group of embodiments is characterized in that the central region is helically wound around the longitudinal axis of the connector pin, whereby the natural material flow during extrusion is even better Account is taken. The mechanical strength is better pronounced. The pin hole to the cavity is closed.
Vorteilhaft ist auch eine Gruppe von Ausführungsformen, bei welchen der Mittelbereich konisch in den Steckerstift eingepresst ist, wobei sich vorzugsweise der konisch geformte Mittelbereich vom Verbindungsende zum steckdosenseitigen Kontaktende hin verjüngt. Damit wird erreicht, dass der Steckerstift einen nochmals verbesserten Torsions- und Ausdruckskraftschutz erhält.Also advantageous is a group of embodiments in which the central region is conically pressed into the plug pin, wherein preferably the conically shaped central region tapers from the connecting end to the socket-side contact end. This ensures that the pin receives a further improved torsional and expressive power protection.
Weil der erzeugte Hohlkonus seinen größten Öffnungsquerschnitt in Richtung auf die in das Crimpende 2a einzuführende Netzanschlusslitze des Steckerkabels besitzt, wird das Einführen der Litze durch eine Führungswirkung erleichtert.Because the hollow cone produced has its largest opening cross-section in the direction of the power cord of the plug cable to be inserted into the
Bei einer alternativen Gruppe von Ausführungsformen schließlich ist der Mittelbereich ballig in den Steckerstift eingepresst. Dadurch kann ebenfalls der Bereich zum Stift verschlossen werden.Finally, in an alternative group of embodiments, the middle region is pressed into the plug pin in a crowned manner. This also allows the area to be closed to the pen.
Weitere Ausführungsformen des erfindungsgemäßen Steckerstifts können vorsehen, dass der Mittelbereich mehrere radiale Querschnittsverengungen in axialer Abfolge längs der Längsachse des Steckerstifts aufweist. Auf diese Weise wird ermöglicht, dass in einer guten Relation zwischen Kraftaufwand und Ergebnis der Steckerstift am Bohrungsgrund verschlossen wird. Dadurch wird der Werkzeugverschleiß in der Herstellung reduziert.Further embodiments of the connector pin according to the invention can provide that the central region has a plurality of radial cross-sectional constrictions in axial sequence along the longitudinal axis of the connector pin. In this way it is possible that in a good relation between force and result of the pin is closed at the bottom of the hole. This reduces tool wear during production.
Bevorzugt sind auch Ausführungsformen des erfindungsgemäßen Steckerstifts, bei weichen das steckdosenseitige Kontaktende eine axiale Länge von 10mm bis 50mm, vorzugsweise von etwa 20mm sowie einen durchgängigen Hohlraum auf einer axialen Länge von 5mm bis 48mm, vorzugsweise auf einer axialen Länge von etwa 18mm aufweist. Mit diesen geometrischen Relationen können die meisten wichtigen Anwendungen des erfindungsgemäßen Steckerstifts abgedeckt werden.Also preferred are embodiments of the connector pin according to the invention, in which the socket-side contact end has an axial length of 10mm to 50mm, preferably of about 20mm and a continuous cavity on an axial length of 5mm to 48mm, preferably on an axial length of about 18mm. With these geometric relations, most important applications of the connector pin according to the invention can be covered.
Ebenso sind Ausführungsformen von Vorteil, die sich dadurch auszeichnen, dass das steckdosenseitige Kontaktende eine axiale Länge von 50% bis 80%, vorzugsweise eine axiale Länge von etwa 2/3 der axialen Gesamtlänge des Steckerstifts sowie einen durchgängigen Hohlraum auf einer axialen Länge von 35% bis 75%, vorzugsweise auf einer axialen Länge von etwa 60% der axialen Gesamtlänge des Steckerstifts aufweist.Likewise embodiments are advantageous, which are characterized in that the socket-side contact end has an axial length of 50% to 80%, preferably has an axial length of about 2/3 of the total axial length of the connector pin and a continuous cavity on an axial length of 35% to 75%, preferably on an axial length of about 60% of the axial total length of the connector pin.
In den Rahmen der vorliegenden Erfindung fällt auch eine Steckerbrücke mit mindestens einem Steckerstift der oben beschriebenen erfindungsgemäßen Art, welche dadurch gekennzeichnet ist, dass sie eine Grundplatte aus thermoplastischem Material, vorzugsweise schwer entflammbarem Kunststoffmaterial umfasst, in welcher mindestens ein Steckerstift eingegossen ist, wobei die Dicke der Grundplatte im Wesentlichen der axialen Länge des Mittelbereichs des mindestens einen Steckerstifts entspricht. Damit lassen sich die gesetzlichen Normvorgaben an Steckerbrücken bezüglich Brandverhütung in den allermeisten Ländern der Welt erfüllen.In the context of the present invention, a plug bridge with at least one plug pin of the type described above according to the invention, which is characterized in that it comprises a base plate made of thermoplastic material, preferably flame retardant plastic material, in which at least one plug pin is cast, wherein the thickness the base plate substantially corresponds to the axial length of the central region of the at least one connector pin. In this way, the statutory standard specifications for plug bridges with regard to fire prevention can be met in the vast majority of countries worldwide.
Weiterhin werden Ausführungsformen dieser Steckerbrücke bevorzugt, welche dadurch gekennzeichnet sind, dass eine elektrische Sicherung gegen zu hohen Stromdurchfluss vorgesehen ist, was in vielen Ländern gesetzlich vorgeschrieben ist.Furthermore, embodiments of this connector bridge are preferred, which are characterized in that an electrical fuse is provided against excessive current flow, which is required by law in many countries.
Vorteilhaft ist auch ein Verfahren zur Herstellung eines Steckerstifts der oben beschriebenen erfindungsgemäßen Art mit einem Verbindungsende zur elektrischen Verbindung mit einer Netzanschlusslitze und einem vom Verbindungsende zu einem steckdosenseitigen Kontaktende führenden elektrisch leitenden Mittelbereich, welches dadurch gekennzeichnet ist, dass in einem ersten Herstellungsschritt (a) aus einem massiven metallischen Rohling durch Umformung, insbesondere durch Tiefziehen oder durch Fließpressumformung ein hohler Rohling erzeugt wird, dass in einem zweiten Herstellungsschritt (b) der zunächst hohle Querschnitt im Mittelbereich des hohlen Rohlings durch konzentrisches Verpressen, Rollieren oder Verjüngen radial zur Achse des hohlen Rohlings derart zusammengepresst wird, dass der Mittelbereich des zusammengepressten Rohlings kunststofffluiddicht und zumindest abschnittsweise massiv ohne durchgängigen Hohlraum zwischen Verbindungsende und steckdosenseitigem Kontaktende ausgebildet wird, und dass anschließend in einem dritten Herstellungsschritt (c) das hohle Verbindungsende des zusammengepressten Rohlings durch Rollieren, Verprägen oder Einschneiden als Crimpende ausgebildet wird, so dass ein Steckerstift zur Herstellung eines elektrischen Kontaktes zwischen einer Netzanschlusslitze eines Steckerkabels und einem Steckdosenkontakt entsteht.Also advantageous is a method for producing a connector pin of the type described above with a connection end for electrical connection to a power cord and leading from the connection end to a plug-side contact end electrically conductive central region, which is characterized in that in a first manufacturing step (a) from a hollow blank is produced by forming, in particular by deep drawing or extrusion molding, that in a second production step (b) the initially hollow cross section in the central region of the hollow blank by concentric pressing, rolling or tapering radially to the axis of the hollow blank in such a way is compressed, that the central region of the compressed blank plastic fluid-tight and at least partially solid without continuous cavity between the connecting end and steckdosenseitigem Contact end is formed, and that then in a third manufacturing step (c), the hollow connection end of the compressed blank is formed by rolling, embossing or cutting as a crimp end, so that a plug pin for establishing an electrical contact between a power cord of a plug cable and a socket contact is formed.
Damit lassen sich erfindungsgemäß modifizierte Steckerstifte in der erforderlichen, sehr hohen Stückzahl und in wirtschaftlichen Taktzeiten kostengünstig produzieren.In this way, according to the invention, modified plug pins can be inexpensively produced in the required, very high number of pieces and in economic cycle times.
Aufgrund der nachträglichen mechanischen Verformung des Mittelbereichs durch das erfindungsgemäß vorgeschriebene Zusammenpressen wird überraschender Weise eine zusätzliche Verfestigung dieser besonders starker Beanspruchung ausgesetzten Region des Steckerstifts erzielt, was nicht von vornherein abzusehen war. Insbesondere verbessert sich dadurch auch die metallische Gefüge-Ausrichtung des Materials in ihrer kristallinen Struktur. Lunker und Verformungsfehler, wie sie bei industrieller Fertigung in hohen Stückzahlen praktisch nicht zu vermeiden sind, spielen bei den nach der erfindungsgemäßen Lehre hergestellten Steckerstiften keine relevante Rolle mehr.Due to the subsequent mechanical deformation of the central region by the compression prescribed according to the invention, an additional strengthening of this region of the connector pin which is subjected to particularly high stress is surprisingly achieved, which was not to be foreseen from the outset. In particular, this also improves the metallic microstructure orientation of the material in its crystalline structure. Voids and deformation errors, as they are practically unavoidable in industrial production in large numbers, play no more relevant role in the connector pins produced according to the teaching of the invention.
Besonders bevorzugt ist eine Variante dieses Verfahrens, bei welcher zumindest zu Beginn des zweiten Herstellungsschritts (b) das im ersten Herstellungsschritt (a) zur Erzeugung des hohlen Rohlings aus dem massiven metallischen Rohling verwendete Umform-Werkzeug mit einem Stempel-Endabschnitt noch auf der axialen Höhe des Verbindungsendes im Hohlraum des hohlen Rohlings sitzt, während der hohle Rohling auf der axialen Höhe des späteren Mittelbereichs des entstehenden zusammengepressten Rohlings radial zur Achse einem konzentrischen Verpressen, Rollieren oder Verjüngen unterzogen wird. Das Stempelende des verwendeten Umform-Werkzeugs wirkt damit beim Zusammenpressen des Mittelbereichs quasi als Gegenlager, was zu einer zusätzlichen - hochgradig erwünschten - Materialverfestigung sowie zu einer besonders gut definierten geometrischen Formgebung der massiven Engstelle(n) beiträgt.Particularly preferred is a variant of this method, wherein at least at the beginning of the second manufacturing step (b) the forming tool used in the first production step (a) for producing the hollow blank from the solid metallic blank with a punch end portion still at the axial height of the connection end is seated in the cavity of the hollow blank, while the hollow blank is subjected to concentric pressing, rolling or tapering at the axial height of the later central region of the resulting compressed blank radially to the axis. The punch end of the forming tool used thus acts as a counter-bearing during compression of the central region, resulting in an additional - highly desirable - material hardening and a particularly well-defined geometric shape of the massive bottleneck (s) contributes.
Weitere Vorteile der Erfindung ergeben sich aus der Beschreibung und der Zeichnung. Ebenso können die vorstehend genannten und die weiter aufgeführten Merkmale je für sich oder zu mehreren in beliebigen Kombinationen Verwendung finden. Die gezeigten und beschriebenen Ausführungsformen sind nicht als abschließende Aufzählung zu verstehen, sondern haben vielmehr beispielhaften Charakter für die Schilderung der Erfindung.Further advantages of the invention will become apparent from the description and the drawings. Likewise, the features mentioned above and those listed further can be used individually or in any combination. The embodiments shown and described are not to be understood as exhaustive enumeration, but rather have exemplary character for the description of the invention.
Es zeigen:
- Fig. 1a
- einen schematischen Längsschnitt durch eine erste Ausführungsform des erfindungsgemäßen Steckerstifts mit in radialer Richtung verpresstem Mittelbereich in einem in die Grundplatte einer Schutzbereich eingebauten Zustand;
- Fig. 1b
- eine Seitenansicht der Ausführungsform nach
Fig. 1 a; - Fig. 2a
- einen schematischen Längsschnitt durch eine zweite Ausführungsform mit um die Längsachse des Stifts verwundenem Mittelbereich;
- Fig. 2b
- eine Seitenansicht der Ausführungsform nach
Fig. 2a ; - Fig. 2c
- einen schematischen Querschnitt in der horizontalen Schnittebene A-A gemäß
Fig. 2b ; - Fig. 3a
- einen schematischen Längsschnitt durch eine dritte Ausführungsform mit konisch eingepresstem Mittelbereich;
- Fig. 3b
- eine Seitenansicht der Ausführungsform nach
Fig. 3a ; - Fig. 3c
- einen schematischen Querschnitt in der horizontalen Schnittebene A-A gemäß
Fig. 3b ; - Fig. 4a
- einen schematischen Längsschnitt durch eine zweite Ausführungsform mit ballig eingepresstem Mittelbereich;
- Fig. 4b
- eine Seitenansicht der Ausführungsform nach
Fig. 4a ; - Fig. 4c
- einen schematischen Querschnitt in der horizontalen Schnittebene A-A gemäß
Fig. 4b ; - Fig. 5
- eine Veranschaulichung der Verfahrensschritte (a) bis (c) anhand von schematischen Längsschnitten der Rohlinge beziehungsweise des Steckerstifts mit dem jeweiligen Verarbeitungswerkzeug in den einzelnen Herstellungsstadien.
- Fig. 1a
- a schematic longitudinal section through a first embodiment of the connector pin according to the invention with compressed in the radial direction central region in a built-in the base plate of a protection area state;
- Fig. 1b
- a side view of the embodiment according to
Fig. 1 a; - Fig. 2a
- a schematic longitudinal section through a second embodiment with wound around the longitudinal axis of the pin central region;
- Fig. 2b
- a side view of the embodiment according to
Fig. 2a ; - Fig. 2c
- a schematic cross section in the horizontal sectional plane AA according to
Fig. 2b ; - Fig. 3a
- a schematic longitudinal section through a third embodiment with a conically pressed central region;
- Fig. 3b
- a side view of the embodiment according to
Fig. 3a ; - Fig. 3c
- a schematic cross section in the horizontal sectional plane AA according to
Fig. 3b ; - Fig. 4a
- a schematic longitudinal section through a second embodiment with crowned pressed central region;
- Fig. 4b
- a side view of the embodiment according to
Fig. 4a ; - Fig. 4c
- a schematic cross section in the horizontal sectional plane AA according to
Fig. 4b ; - Fig. 5
- an illustration of the method steps (a) to (c) based on schematic longitudinal sections of the blanks or the connector pin with the respective processing tool in the individual stages of manufacture.
In den verschiedenen Figuren der Zeichnung sind der Übersichtlichkeit wegen gleiche Merkmale jeweils mit gleichen Bezugszeichen bezeichnet.In the various figures of the drawing, the same features are designated by the same reference numerals for clarity.
Die
In
Technisch möglich und für spezielle Anwendungen durchaus vorteilhaft sind weitere - allerdings in der Zeichnung nicht dargestellte - Ausführungsformen des erfindungsgemäßen Steckerstifts, bei welchen der Mittelbereich mehrere radiale Querschnittsverengungen in axialer Abfolge längs der Längsachse des Steckerstifts aufweist.Technically feasible and quite advantageous for specific applications are further embodiments of the inventive plug pin (not shown in the drawing) in which the central region has a plurality of radial cross-sectional constrictions in axial sequence along the longitudinal axis of the plug pin.
- In einem ersten Herstellungsschritt (a) wird aus einem massiven metallischen Rohling 1' durch Umformung, insbesondere durch Tiefziehen oder durch Fließpressumformung ein hohler Rohling 1" erzeugt.
- In a first production step (a) , a hollow blank 1 "is produced from a solid metallic blank 1 ' by deformation, in particular by deep-drawing or by extrusion molding.
In einem zweiten Herstellungsschritt (b) wird der zunächst hohle Querschnitt im Mittelbereich 4 des hohlen Rohlings 1" durch konzentrisches Verpressen, Rollieren oder Verjüngen radial zur Längsachse des hohlen Rohlings 1" derart zusammengepresst, dass der Mittelbereich 4 des zusammengepressten Rohlings 1"' kunststofffluiddicht und zumindest abschnittsweise massiv ohne durchgängigen Hohlraum zwischen Verbindungsende 2 und steckdosenseitigem Kontaktende 3 ausgebildet wird.In a second production step (b) , the initially hollow cross-section in the central region 4 of the hollow blank 1 "is compressed by concentric pressing, rolling or tapering radially to the longitudinal axis of the hollow blank 1" such that the central region 4 of the compressed blank 1 "'plastic fluid-tight and is at least partially solid without continuous cavity between the
Anschließend wird in einem dritten Herstellungsschritt (c) das hohle Verbindungsende 2 des zusammengepressten Rohlings 1'" durch Rollieren, Verprägen, Einschneiden oder ähnliche bekannte Verarbeitungsverfahren als Crimpende 2a ausgebildet, so dass schließlich ein erfindungsgemäßer Steckerstift 1 zur Herstellung eines elektrischen Kontaktes zwischen einer Netzanschlusslitze eines Steckerkabels und einem Steckdosenkontakt entsteht.Subsequently, in a third production step (c), the hollow connecting
Zumindest zu Beginn des zweiten Herstellungsschritts (b) sitzt das im ersten Herstellungsschritt (a) zur Erzeugung des hohlen Rohlings 1" aus dem massiven metallischen Rohling 1' verwendete Umform-Werkzeug mit einem Stempel-Endabschnitt noch auf der axialen Höhe des Verbindungsendes 2 im Hohlraum des hohlen Rohlings 1", während der hohle Rohling 1" auf der axialen Höhe des späteren Mittelbereichs 4 des entstehenden zusammengepressten Rohlings 1'" radial zur Achse einem konzentrischen Verpressen, Rollieren oder Verjüngen unterzogen wird. Dadurch kann dann das Stempelende des Werkzeugs als Gegenlager bei der im dritten Herstellungsschritt (c) erfolgenden radialen Verformung und Verfestigung des Mittelbereichs 4 wirken.At least at the beginning of the second production step (b), the forming tool used in the first production step (a) for producing the hollow blank 1 "from the solid metallic blank 1 'still has a punch end section at the axial height of the connecting
- 11
- Steckerstiftpin
- 1.11.1
- Steckerstift mit radial verpresstem MittelbereichConnector pin with radially compressed central area
- 1.21.2
- Steckerstift mit verwundenem MittelbereichPin with twisted middle section
- 1.31.3
- Steckerstift mit konisch eingepresstem MittelbereichConnector pin with conically pressed middle section
- 1.41.4
- Steckerstift mit ballig eingepresstem MittelbereichConnector pin with convex pressed central area
- 1'1'
- massiver metallischer Rohlingmassive metallic blank
- 1"1"
- hohler Rohlinghollow blank
- 1'"1'"
- im Mittelbereich zusammengepresster Rohlingin the middle area compressed blank
- 22
- Verbindungsendeconnecting end
- 2a2a
- Crimpendecrimping
- 33
- KontaktendeContact end
- 44
- Mittelbereichthe central region
- 4.14.1
- in radialer Richtung verpresster Mittelbereichin the radial direction compressed central region
- 4.24.2
- um die Längsachse des Stifts verwundener Mittelbereicharound the longitudinal axis of the pin twisted middle area
- 4.34.3
- konisch eingepresster Mittelbereichconically pressed center area
- 4.44.4
- ballig eingepresster Mittelbereichcrowned central area
- 55
- Steckerbrücken-GrundplattePlug bridge base plate
- aa
- Längsachse des SteckerstiftsLongitudinal axis of the connector pin
Claims (15)
- Plug pin (1; 1.1; 1.2; 1.3; 1.4) for producing an electrical contact between a mains connection strand of a plug cable and a socket contact, the plug pin (1; 1.1; 1.2; 1.3; 1.4) comprising a longitudinal axis (a), a connecting end (2) for electrical connection to the mains connection strand and an electrically conducting central area (4; 4.1; 4.2; 4.3; 4.4) that extends from the connecting end (2) to a contact end (3) on the side of the socket, wherein the connecting end (2) is formed as a hollow crimp end (2a) and wherein the connecting end (2) and at least part of the contact end (3) on the side of the socket are formed to be hollow through deep drawing or extrusion shaping,
characterized in that
the central area (4; 4.1; 4.2; 4.3; 4.4) is formed by concentric compression, rolling or tapering of wall parts of the central area (4; 4.1; 4.2; 4.3; 4.4) in a radial direction with respect to the axis to be plastic fluid-tight, and is formed at least in sections to be solid without continuous cavity between the connecting end (2) and the contact end (3) on the socket side. - Plug pin according to claim 1, characterized in that the central area (4; 4.1; 4.2; 4.3; 4.4) has an axial length of 3mm to 8mm, preferably an axial length of approximately 5mm and is formed to be solid without continuous cavity between the connecting end (2) and the contact end (3) on the socket side along an axial length of 1mm to 3mm, preferably along an axial length of approximately 2mm.
- Plug pin according to claim 1 or 2, characterized in that the central area (4; 4.1; 4.2; 4.3; 4.4) has an axial length of 10% to 20%, preferably an axial length of approximately 15%, of the overall axial length of the plug pin (1; 1.1; 1.2; 1.3; 1.4) and is formed to be solid without continuous cavity between the connecting end (2) and the contact end (3) on the socket side along an axial length of 5% to 10%, preferably along an axial length of approximately 7% of the overall axial length of the plug pin (1; 1.1; 1.2; 1.3; 1.4).
- Plug pin according to any one of the preceding claims, characterized in that along the axial length of that section or those sections which are formed to be solid without continuous cavity, the outer circumference of the central area (4; 4.1; 4.2; 4.3; 4.4) has at least one cross-sectional narrowing to at least 25% to 75%, preferably to approximately 2/3, of the cross-section of the other sections of the central area (4; 4.1; 4.2; 4.3; 4.4).
- Plug pin according to any one of the claims 1 through 4,
characterized in that the central area (4.1) is compressed in a radial direction transversely to the longitudinal axis (a) of the plug pin (1.1). - Plug pin according to any one of the claims 1 through 4,
characterized in that the central area (4.2) is helically wound around the longitudinal axis (a) of the plug pin (1.2). - Plug pin according to any one of the claims 1 through 4,
characterized in that the central area (4.3) is conically pressed into the plug pin (1.3), wherein the conically shaped central area (4.3) preferably tapers from the connecting end (2) towards the contact end (3) on the socket side. - Plug pin according to any one of the claims 1 through 4,
characterized in that the central area (4.4) is spherically pressed into the plug pin (1.4). - Plug pin according to any one of the preceding claims, characterized in that the central area has a plurality of radial cross-sectional narrowings in axial sequence along the longitudinal axis of the plug pin.
- Plug pin according to any one of the preceding claims,
characterized in that the contact end (3) on the socket side has an axial length of 10mm to 50mm, preferably of approximately 20mm and a continuous cavity along an axial length of 5mm to 48mm, preferably along an axial length of approximately 18mm. - Plug pin according to any one of the preceding claims,
characterized in that the contact end (3) on the socket side has an axial length of 50% to 80%, preferably an axial length of approximately 2/3, of the overall axial length of the plug pin (1; 1.1; 1.2; 1.3; 1.4) and a continuous cavity along an axial length of 35% to 75%, preferably along an axial length of approximately 60%, of the overall axial length of the plug pin (1; 1.1; 1.2; 1.3; 1.4). - Plug bridge comprising at least one plug pin (1; 1.1; 1.2; 1.3; 1.4) according to any one of the preceding claims, characterized in that the plug bridge comprises a base plate (5) of thermoplastic material, preferably hardly inflammable plastic material, into which at least one plug pin (1; 1.1; 1.2; 1.3; 1.4) is cast, wherein the thickness of the base plate (5) substantially corresponds to the axial length of the central area (4; 4.1; 4.2; 4.3; 4.4) of the at least one plug pin (1; 1.1; 1.2; 1.3; 1.4).
- Plug bridge according to claim 12, characterized in that an electrical fuse is provided as protection against an excessive current flow.
- Method for producing a plug pin (1; 1.1; 1.2; 1.3; 1.4) according to any one of the claims 1 through 11 comprising a connecting end (2) for electrical connection to a mains connection strand and an electrically conducing central area (4; 4.1; 4.2; 4.3; 4.4) which extends from the connecting end (2) to a contact end (3) on the socket side, characterized in that in a first production step (a) a hollow blank (1") is produced from a solid metallic blank (1') through shaping, such as deep drawing or extrusion shaping,
that in a second production step (b) the initially hollow cross-section in the central area (4; 4.1; 4.2; 4.3; 4.4) of the hollow blank (1") is compressed by concentric compression, rolling or tapering radially with respect to the axis of the hollow blank (1") in such a manner that the central area (4; 4.1; 4.2; 4.3; 4.4) of the compressed blank (1"') is formed to be plastic fluid-tight and at least in sections solid without continuous cavity between connecting end (2) and contact end (3) on the socket side,
and that subsequently in a third production step (c) the hollow connecting end (2) of the compressed blank (1"') is formed as a crimp end (2a) by rolling, embossing or cutting such that a plug pin (1) is produced for producing an electrical contact between a mains connection strand of a plug cable and a plug contact. - Method according to claim 14, characterized in that at least at the beginning of the second production step (b), a punch end section of the forming tool used in the first production step (a) for producing the hollow blank (1") from the solid metallic blank (1') is still seated at the axial height of the connecting end (2) in the cavity of the hollow blank (1"), whereas the hollow blank (1") is subjected to concentric compression, rolling or tapering in a radial direction with respect to the axis at the axial height of the future central area (4; 4.1; 4.2; 4.3; 4.4) of the compressed blank (1"') to be produced.
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
DE202013101939U DE202013101939U1 (en) | 2013-05-03 | 2013-05-03 | Part-massive hollow pin |
Publications (2)
Publication Number | Publication Date |
---|---|
EP2800205A1 EP2800205A1 (en) | 2014-11-05 |
EP2800205B1 true EP2800205B1 (en) | 2016-04-06 |
Family
ID=48608368
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP14166028.2A Active EP2800205B1 (en) | 2013-05-03 | 2014-04-25 | Partially solid hollow pin |
Country Status (2)
Country | Link |
---|---|
EP (1) | EP2800205B1 (en) |
DE (1) | DE202013101939U1 (en) |
Families Citing this family (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN106299827B (en) * | 2016-10-20 | 2019-01-18 | 浙江恒达高电器有限公司 | Socket and its assembly method |
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US2563761A (en) * | 1945-09-20 | 1951-08-07 | Bendix Aviat Corp | Socket connector having an indented solder wall |
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DE8912290U1 (en) | 1989-10-17 | 1989-12-28 | Interconnectron Gesellschaft für industrielle Steckverbindungen mbH, 94469 Deggendorf | Electrical cable connector |
DE4314195A1 (en) | 1993-04-30 | 1994-11-03 | M & K Metall Und Kunststoff Gm | Plug pin and plug link |
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DE19627335C1 (en) | 1996-06-28 | 1997-09-04 | Taller Gmbh | Contact pin for bridge of pluggable electric connector |
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FR2796765B1 (en) | 1999-07-20 | 2001-10-05 | Fci France | STRIP OF CONTACT SUPPORTS AND METHOD FOR DETACHING A CONTACT MAINTAINED ON THIS STRIP |
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DE10151990A1 (en) | 2001-10-22 | 2003-04-30 | Taller Gmbh | Two-part plug pin has tubular body and rounded head end formed as separate components permanently secured together |
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DE102007009422A1 (en) | 2007-02-23 | 2008-09-25 | Taller Gmbh | pin |
WO2009021491A2 (en) | 2007-08-13 | 2009-02-19 | Global Genius (Hong Kong) Limited | Plug pin formed using an extrusion process |
DE102007062500A1 (en) | 2007-12-20 | 2009-06-25 | Michael Taller | Plug pin for use in e.g. plug bridge, has connection end for connection to connection wire, and middle area leading from connection end to contact end, where connection end is designed as crimped end and middle area is designed to be hollow |
DE202007018665U1 (en) | 2007-08-13 | 2009-01-22 | Taller, Michael | pin |
DE102007039324A1 (en) | 2007-08-20 | 2009-02-26 | Michael Taller | Hollow pin for plug bridge in power line in electrical device, has hollow pin axis, and wire connection end that is coaxially aligned to stop wire to hollow pin axis, where pin is integrally formed from stamped sheet metal |
DE202007017752U1 (en) * | 2007-08-23 | 2009-01-02 | Kazmierczak, Udo | Connector bridge with plug hollow pin |
DE102009049369B4 (en) | 2009-10-14 | 2011-06-22 | Taller GmbH, 76337 | Plug bridge with folding pins |
DE102009052950B4 (en) | 2009-11-12 | 2011-09-01 | Taller Gmbh | Appliance plug in half-shell design with injected pins and spring-loaded contact elements |
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-
2013
- 2013-05-03 DE DE202013101939U patent/DE202013101939U1/en not_active Expired - Lifetime
-
2014
- 2014-04-25 EP EP14166028.2A patent/EP2800205B1/en active Active
Also Published As
Publication number | Publication date |
---|---|
DE202013101939U1 (en) | 2013-05-15 |
EP2800205A1 (en) | 2014-11-05 |
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