EP2932563A1

EP2932563A1 - Contact element and method for producing a contact element

Info

Publication number: EP2932563A1
Application number: EP13750029.4A
Authority: EP
Inventors: Reza HOSSAINI; Matthias Haucke; Markus Ofenloch; Peter Kraemer; Ufuk TUEY; Mohamed Aboulkassem
Original assignee: TE Connectivity Germany GmbH
Current assignee: TE Connectivity Germany GmbH
Priority date: 2012-12-13
Filing date: 2013-08-12
Publication date: 2015-10-21
Anticipated expiration: 2033-08-12
Also published as: US9705227B2; WO2014090422A1; CN104981945B; US20150357740A1; DE102012223082A1; CN104981945A; EP2932563B1

Abstract

The invention relates to a contact element (1) of an electrically conducting contact material (4) for establishing an electrically conducting connection, with a connector end (3) for plugging into a complementary mating contact element, particularly a socket, and a conductor end (5), to which an electrical conductor can be fastened, wherein a connector-end cross-section (17) of the contact element (1) is larger than a conductor-end cross-section (19), and a method for producing a contact element (1). In order to be able to produce contact elements (1) quickly and at low cost, it is proposed according to the invention that there is at least one fold (7) of the contact material (4) at the connector end (3) and that the contact material (4) is folded over at least once from the contact end (3) towards the conductor end (5).

Description

Contact element and method for producing a contact element

The invention relates to a contact element made of an electrically conductive contact material for producing an electrically conductive connection, with a plug-side end for mating with a complementary mating contact element, in particular a socket, and a conductor-side end to which an electrical conductor can be fastened, wherein a plug-side Cross-section of the contact element is greater than a conductor-side cross-section. Furthermore, the invention relates to a method for producing a contact element according to the invention.

Contact elements, in particular plugs, have long been known and are used in numerous electrical and electronic devices. Contact elements are usually heavily stressed by repeated attachment to and release from a mating contact element, so that they must have on the plug side a stress sufficient strength. This is usually realized by a sufficiently high material thickness at the plug end. At the conductor end, on the other hand, it is necessary for the contact element to have a small material thickness in order to be connected to a conductor, e.g. To connect by crimping such as crimping.

Heretofore, such contact elements have been made by being made from one piece of starting material by means of exciting methods, e.g. Milling be shaped. The resulting surfaces often still have to be smoothed and / or coated. This production method requires many production steps, consumes much material due to the removal and is therefore complicated and expensive.

Another known method is the joining of sections of different thicknesses to a contact element. This method is complicated and thus expensive, since the sections are usually insoluble, e.g. must be joined together by welding. It is therefore the object of the invention to provide a contact element that can be easily and inexpensively manufactured, and a method for producing such a contact element.

This object is achieved for the above-mentioned contact element in that at the plug-side end at least one envelope of the contact material is present. For the method mentioned at the outset, the object is achieved in that the contact material is turned over at least once from the connector-side end in the direction of the conductor-side end. Due to the simple structure of the contact element this is inexpensive to manufacture. It also has the required strength for repeated bonding and loosening, and can be made in different dimensions using the same starting material.

The solution according to the invention can be further improved by various configurations which are each advantageous and which can be combined with one another as desired. In these embodiments and the advantages associated with you will be discussed below, the design measures and their effects are described only as an example of a contact element with an envelope. Of course, at the contact element, in particular its plug-side end, also several envelopes may be present. The contact element may have an elongated basic shape. It has a plug-side end for mating with a complementary mating contact element, in particular a socket, and a conductor-side end to which an electrical conductor can be fastened.

Among others, cables or strip conductors can be used as conductors. The conductors can be attached to the conductor-side end of the contact element by common methods. In particular, they can be soldered or pressed by crimping to the conductor end. For crimping, a lower material thickness is required at the conductor-side end than at the plug-side end, therefore the conductor-side end can be formed from only one layer of the contact material.

The contact material may be chosen so that the desired type of connection, in particular crimping, can be realized without the material thickness of the contact material having to be changed in an initial shape by machining processes.

At the plug-side end, the invention provides that at least one envelope of the contact material is present. The envelope may be formed from the contact material by bending, bending or other suitable method. At the plug-side end of the contact element can be formed by the envelope formed from at least two contact layers multilayer region of the contact material.

From the plug-side end in the direction of the conductor-side end of the contact element, a continuous and smooth contact region for repeatedly releasable connection to a complementary counter-contact element may extend on the outer sides of the outer contact layers of the multilayer region. The plug-side cross section mentioned at the beginning is measured through the multilayer region perpendicular to a surface of the contact region. The plug-side cross-section is larger than the conductor-side cross-section, which is determined by the thickness of the contact material. The plug-side cross section of the contact element through the multilayer region can be at least twice as large as the conductor-side cross section.

Due to the larger cross-section, the plug-side end is difficult to deform and well suited for repeated loosening and fastening of the contact element.

The continuous and smooth contact area is particularly advantageous since it is free of disturbances such as e.g. Burrs, folds or welds is. The contact element can thus be easily assembled with the complementary mating contact element.

Since the contact area is continuous and contains no constrictions or openings, it can be avoided that damage caused by overheating due to high current densities in narrow areas of the contact area. The envelope may be tapered in a plugging direction. The rejuvenation can be pointed or rounded. The rounded taper is particularly advantageous for a contact element because it has no burrs, welds or similar imperfections. It is essentially smooth and can therefore be inserted particularly easily into a mating contact element, such as e.g. a socket are inserted. The envelope may form a head of the contact element. If the envelope is formed by a manufacturing process that results in edges, the taper may be formed from a sequence of multiple edges. The sequence of edges can be designed so that the tip is well suited for easy insertion into a mating contact element.

At least one spacer may be present, by which the at least two contact layers of the multi-layer area are kept at a distance from one another. Due to the size of the spacers, the number of contact layers and the thickness of the contact material, the cross section of the contact element may be determined at the plug end.

The at least one spacer may be formed from at least one deformed region of the contact material. This is particularly advantageous, since in the production of the contact element no additional components have to be added, but the spacer can be formed directly from the contact material by suitable techniques such as bending or other forming processes.

The at least one spacer may be formed from at least one deformed edge of a contact layer of the multilayered region, wherein the deformed edge may be adjacent to an adjacent contact layer. This shape of the spacer is particularly advantageous since it is located at the edge of the multi-layer area, whereby the largest possible continuous contact area is formed.

At least one of the contact layers may have at least one closure element which, in an assembled state, is positively accommodated in at least one associated complementary recess on another layer of the multilayer region, in particular on an adjacent contact layer. The closure elements can prevent bending of the contact element after manufacture. This is particularly advantageous because it allows a long life and frequent use of the contact element.

The at least one closure element can be pressed by friction with an associated recess. A frictional pressing of a closure element with an associated recess is particularly advantageous because it can be dispensed with complex connection techniques such as soldering or welding.

At least one closure element and / or its associated recess may be tapered in the direction of the associated recess. This embodiment facilitates frictional pressing of the closure element with the associated recess in the production process.

From the plug-side end, at least one projecting latching tongue may extend in the direction of the conductor-side end, the latching tongue having a foot at its plug-side end and a free latching tongue end at the ladder-side end. The latching tongue can be formed from a contact layer of the multilayered area. The latching tongue can be arranged in particular at an angle between 0 ° and 90 ° to a surface of the single-layer area at the conductor-side end.

The contact element may have at least one support element which extends from the plug-side end in the direction of the conductor-side end and bears against the surface of another contact layer, in particular an adjacent one. The support element can in particular Keep an open end of a contact layer of the multi-layered area at a distance from the adjacent contact layer. It therefore contributes to the stability of the plug end.

The at least one support element can abut with its conductor-side end in an area between the foot and the free latching tongue end of the latching tongue on the surface of the single-ply region. This is particularly advantageous since the support elements maintain the spacing of the contact layers in the multilayer region even when a pressure is exerted on the latching tongue.

In a particularly advantageous embodiment, the contact element may have a reinforcement region which extends behind the multilayer region in the direction of the conductor-side end, wherein the reinforcement region is formed from at least two reinforcement layers. The reinforcing layers in the reinforcing region can provide additional stability to the contact element.

The reinforcing region may comprise at least one further envelope of the contact material, wherein the further envelope may be formed by folding the contact material in a direction other than the envelope of the multilayer region, and the at least two reinforcing layers may be joined by the at least one further envelope. This at least one envelope additionally increases the stability. The production of the reinforcing layers by folding over can be incorporated easily and therefore inexpensively into the production process of the contact element. At least one of the reinforcing layers may comprise at least one spacer by which at least two of the reinforcing layers are spaced from each other. These spacers can prevent compression of the two reinforcing layers and thereby give the contact element dimensional stability in the reinforcing region.

At least one of the reinforcement layers may be connected directly or indirectly positively and / or frictionally with at least one of the contact layers of the multi-layered region. The combination of reinforcing layers with contact layers produces a particularly dimensionally stable contact element.

The interconnected reinforcing layers and contact layers may have interlocking elements which automatically engage in the manufacture of the contact element by folding into each other and produce the positive and frictional connection. In this case, the region of the contact material which forms the envelope of the multi-layered region at the plug-side end can have a widening, in particular an undercut widening.

In the production, a region of the contact material, which forms a reinforcing layer as a cover in the installed state, may have a head-shaped region which, when folded over, can be pressed into the undercut widening of a contact layer and thereby connect reinforcing layer and contact layer.

The head-shaped region can have a deformation region, in particular an opening or an incision, which allows an elastic deformation of the head region. If the head area is pressed into the expansion, the head can be deformed elastically, since the head is compressed in the direction of the deformation area. The head can then exert pressure on the expansion. As a result, contact and reinforcement layer can also be connected to each other by friction.

Alternatively, the expansion in the reinforcement layer and the head-shaped region in the contact layer may be present.

In order to obtain a particularly stable contact element, the contact element may comprise at least one spacer which extends from a contact position in the direction of the reinforcing layers, wherein a support region of the spacer is arranged between the reinforcing layers of the reinforcing region. In order to further increase the stability of a contact element, the support region of the spacer may extend at least partially parallel to the reinforcing layers.

In order to further improve the stability of the multilayer region, the at least one spacer may have a securing section which projects at least partially into at least one positive-locking opening in at least one of the reinforcing layers. At least one of the reinforcing layers may be penetrated by a latching tongue extending from another reinforcing layer. Thus, a latching tongue can also be used when using reinforcing layers.

The reinforcing region may comprise at least one securing element for preventing the laying of the latching tongue in the direction of the contact element. This can ensure that the latching tongue is bent back into the contact element. The contact element may have a head portion which is disposed at the plug-side end of the multi-layered portion and include the envelope of the contact material and thus the head of the contact element. The head width can be determined by the width of the head at the plug-side end and the connector width by the width of the plug in the multi-layer area outside the head area. The head width can be smaller than the connector width. If the head width is smaller than the connector width, then the head region can represent a narrowing of the width of the contact element, which can facilitate a mating of the contact element with a mating contact element.

At least two contact elements with spacers of different dimensions can be formed. These contact elements can together form a sentence. The contact elements may have different cross-sections at their plug-side end.

The contact element can be produced by turning the contact material at least once from the plug-side end in the direction of the conductor-side end. When turning over the contact material, it is possible to use e.g. Punching prefabricated interlocking elements engage each other and thereby form-locking connection with each other when turning different layers of the contact element.

This method is particularly advantageous because no machining processes are needed. The contact material may be in its original form as a stampable material e.g. The thickness of the sheet may preferably determine the cross-section of the contact material at the conductor-side end of the contact element.

The invention is explained below by way of example with reference to two exemplary embodiments with reference to the drawings.

1 shows a schematic side view of a first exemplary embodiment of the contact element according to the invention;

Fig. 2 is a schematic illustration of a part of the plug-side end of the first embodiment; Fig. 3 is a schematic representation of the plug-side end of the first embodiment in an enlarged view;

Fig. 4 is a schematic representation of the area around the latching tongue of the first embodiment; Fig. 5 is a schematic representation of a second embodiment;

Fig. 6 is a schematic rear view of the second embodiment;

7 is a perspective view of a third embodiment of the contact element according to the invention;

8 shows a longitudinal section through the third embodiment; 9 is an enlarged view of a portion of the longitudinal section of the third embodiment;

10 shows a section through a region around a spacer of the third embodiment;

1 1 is a perspective view of a fourth embodiment of the inventive contact element.

12 shows a longitudinal section through a contact element according to the fourth embodiment;

Fig. 13 is an enlarged view of a portion of the longitudinal section of the fourth embodiment;

14 shows a section through a spacer according to the fourth embodiment; and FIG. 15 shows a cross section through an area around the latching tongue of the fourth exemplary embodiment.

1 shows a side view of a first exemplary embodiment of a contact element 1 according to the invention. The contact element 1 consists of the contact material 4 and has a plug-side end 3 for mating with a mating contact element, and a conductor-side end 5 for connection to an electrical conductor. The contact element 1 has two contact layers 11: a connector layer 11b passing through from the conductor-side end 5 to the plug-side end 3, and a shorter cover layer 11a extending over the plug-side end 3. The two contact layers 11a and 11b together form the multilayer region 9. The turn-over layer 11a has an open end 12 pointing in the direction of the conductor-side end 5.

The plug-side end 3 is essentially formed from the multilayer region 9. The multilayer region 9 is formed by folding over the contact material 4. The two contact layers 1 1 a and 1 1 b are substantially parallel to each other and spaced from each other. The envelope 7 of the contact material 4 is tapered in the insertion direction 2 and forms the head 21 of the contact element. The plug-side cross section 17 is larger than the conductor-side cross section 19.

Spacer 23 hold the two contact layers 1 1 a and 1 1 b of the multilayer area 9 at a defined distance from each other. The spacer 23 is formed from a deformed region 24 of the turnup layer 11a. An edge 30 of the turn-over layer 1 1 a is formed as a spacer 23 in the direction of the plug layer 1 1 b. The spacer 23 is applied to the connector layer 1 1 b, which in this case, the Umschlaglage 1 1 a adjacent contact layer 1 1.

The spacers 23 are bounded by the closure elements 27. The closure elements 27 are formed by forming a portion of the plug layer 1 1 b. They are in the assembled state 28 in recesses 29 of the envelope layer 1 1 a positively received. The closure elements 27 are pressed into the recesses 29. The closure elements 27 connect the two contact layers 1 1 a and 1 1 b of the multilayer region 9 with each other, so that the contact layers 1 1 a and 1 1 b can not be separated from each other. The closure elements 27 and the spacers 23 therefore ensure the dimensional stability of the contact elements.

The closure elements 27 may be tapered in the direction of the recesses 29. Likewise, the recesses 29 may be widened in the direction of the closure elements 27. As a result, the compression is facilitated in the production.

The outer sides 14 of the outer contact layers 16 of the multilayer region 9 form the contact region 13 of the contact element 1. This contact region 13 is substantially smooth and continuous and therefore particularly advantageous for the mating of the contact element 1 with a mating contact element such as a socket. If the envelope 7 is formed by bending the contact material 4, the head 21 may be rounded. This facilitates the insertion of the contact element 1 in a mating contact element. If, on the other hand, the envelope 7 is formed by edge-forming methods such as folding, then the head 21 can have edges which ensure a smooth insertion of the contact element 1 into a mating contact element when a tapering of the envelope 7 in the plug-in direction 2 is maintained.

From the open end 12 of the turnup 11 1 a, a latching tongue 31 extends in the direction of the conductor end 5. Their free locking tongue end 35 is from the Umschlaglageebene 32 of the contact element 1 and has substantially in the direction of the conductor end 5. The latching tongue 31 can Attach the contact element 1 in a contact housing.

From the open end 12 support members 37 extend in the direction of the conductor-side end 5. The support members 37 are located on a surface 39 on the inside of the plug layer 1 1 b. The support members 37 hold in the region of the latching tongue 31, the two contact layers 1 1 a and 1 1 b of the multilayer region 9 spaced from each other. If a force is exerted on the latching tongue 31 in the direction of the adjacent plug layer 11 b by a load on the contact element 1, then the support elements 37 prevent the two plies 11 a and 11 b from being compressed. As a result, the cross section 17 of the multi-layer area 9 is maintained, which ensures the secure fit of the contact element 1 in a mating contact element. The conductor-side end 5 of the contact element 1 is used for connection to an electrical conductor, such as e.g. a cable. Since the conductor-side end 5 is essentially formed from a single-layer region 15, it is particularly suitable for pressing with a conductor, in particular for crimping.

FIG. 2 shows a schematic representation of part of the plug-side end 3 of the exemplary embodiment from FIG. 1. A pair of closure elements 27 is shown here in section. The contact region 13 is essentially formed from the outer contact layers 16 of the multilayer region 9. The surface 41 of the contact region 13 is substantially smooth and extends continuously from the plug-side end 3 in the direction of the conductor-side end 5. The contact region 13 is free of disturbances such as burrs, seams, welds or openings. It ensures a particularly smooth contact of the contact element 1 with a Counter contact element and a trouble-free electrical connection with the mating contact element.

The closure elements 27 are formed by forming a portion of the plug layer 1 1 b. They are positively received in recesses 29 in the turnover position 1 1 a. The spacers 23 are delimited in the longitudinal direction 43 by the closure elements 27.

Fig. 3 shows the plug-side end 3 of the first embodiment of a contact element 1 according to the invention in an enlarged view, wherein a region with spacers 23 is shown in section.

The spacers 23 are formed from deformed regions 24 of the turn-up layer 11a in the multi-layer region 9. The edges 30 of the turnup layer 1 1 a are formed along the longitudinal direction 43 of the contact element 1 in the direction of the plug layer 1 1 b. The spacers 23 shown in Fig. 3 are deformed by bending the edges 30. They can also be formed by folding or other forming methods.

The deformed edges 30 form the spacers 23 and lie against the plug layer 1 1 b. The spacers 23 keep the two contact layers 1 1 a and 1 1 b of the multilayer region 9 spaced from each other. The spacers 23 are bounded in the longitudinal direction by the closure elements 27.

The spacers 23 are formed continuously between the delimiting closure elements 27 and lie continuously against the plug layer 11 b. Alternatively, they can also be formed from several transformations. Instead of bending methods, other methods such as stamping or embossing may also be used to make the spacers.

4 shows the area around the latching tongue 31 of the first exemplary embodiment in a schematic representation.

The latching tongue 31 extends from the turn-over layer 11a in the direction of the conductor-side end 5 of the contact element 1. The latching tongue 31 points away from the contact element 1. The foot 33 of the latching tongue 31 is connected to the envelope layer 1 1 a. When mounting the contact element 1 in a suitable receptacle such as a plug housing, the latching tongue end 35 can be in direct contact with this and serves for the secure attachment of the contact element. 1 The support members 37 extend from the turnup 11 1 a in the direction of the conductor-side end 5. The support members 37 are formed from deformed areas of the turnup 11 1 a. The support elements 37 shown in Fig. 4 are formed by bending. Alternatively, support elements may also be formed by other suitable methods, such as embossing. The support elements 37 abut against a surface 39 of an inner side of the adjacent plug layer 11 b. In the longitudinal direction 43 are the support elements 37 between the foot ß 33 and the locking tongue end 35 of the latching tongue 31 on the surface 39 of the connector layer 1 1 b.

5 shows a further exemplary embodiment of a contact element 1 according to the invention.

For components which correspond in function and / or construction to the components of the previously described embodiment of FIGS. 1 to 4, the same reference numerals are used. For the sake of brevity, only the differences from the previously described embodiment will be discussed.

The contact element 1 has a reinforcement region V, which extends from the end of the multilayer region 9 in the direction of the conductor-side end 5. The turnup 11 1 a is shortened at its open end 12 compared to the previous embodiment.

The reinforcing region V has two envelopes 45 running parallel to the longitudinal direction 43, which are formed by folding over the edges 47 of the plug layer 11b running parallel to the longitudinal direction 43 in an envelope direction 46 towards the contact element 1.

In the production of the contact element, the plug layer 1 1 b initially broader than in the previously described embodiment can be formed to provide contact material 4 for the longitudinal envelopes 45 of the edges 47 ready.

The longitudinal envelopes 45 form a Umfaltlage 20a, which is substantially parallel to the connector layer 1 1 b and connects at its pointing in the direction of insertion 2 end 49 to the turn-up position 1 1 a of the multi-layer area 9. The Umfaltlage 20 a and the connector layer 1 1 b represent the reinforcing layers 20 in the gain region V.

In this exemplary embodiment, the fold-over layer 20a is formed from two folded edges 47 of the plug layer 11b. Alternatively, the Umfaltlage 20a from the envelope of a single edge 47 of the connector layer 1 1 b may be formed. The reinforcing layers 20 give the contact element 1 additional stability.

In order to prevent compression of the reinforcing layers 20 of the contact element 1 in the gain region V, the plug layer has 1 1 b spacers 51st These can be achieved by suitable forming techniques such as i.a. Punching, punching or bending in the connector layer 1 1 b be formed.

For dimensionally stable connection with the turn-up position 11a of the multi-layer area 9, the fold-over layer 20a has connection extensions 53. The connection extensions 53 are inserted in a form-fitting manner into a complementary receiving opening 55 in the turn-up position 11a.

The receiving opening 55 is keyhole-shaped and extends to the conductor-side end 57 of the turnup 11 1 a, so that the connection extensions 53, which extend from the Umfaltlage 20a, can engage in the receiving openings 55.

The connection extensions 53 have neck portions 53a and head portions 53b. The receiving opening 55 has an undercut 55a. The undercut 55a engages in the neck areas 53a of the connection extensions 53. Between the head areas 53b there is a deformation area 53c. When the connecting extensions 53 are pressed into the receiving opening 55, the head regions 53b are pressed elastically in the direction of the deformation region 53c and exert a pressure on the receiving opening 55. As a result, the turn-over layer 11a is frictionally and positively connected to the reinforcing layer 20a. This secures the connection of the turn-over layer 11a with the fold-over layer 20a against tensile and compressive forces along the longitudinal direction 43 and transversely thereto.

The latching tongue 31 extends in this embodiment of the connector layer 1 1 b. The folded-over layer 20a has a latching tongue opening 59, through which the latching tongue 31 protrudes from the plug-in layer 11b. The latching tongue opening 59 is substantially rectangular, with its longitudinal sides 61 running parallel to the longitudinal direction 43 of the contact element 1.

The latching tongue opening 59 is dimensioned and arranged such that the latching tongue 31 protrudes unhindered through it and can therefore be used.

At the conductor-side end 63 of the latching tongue opening 59 there are two securing elements 65 which prevent the latching tongue 31 from bending back in the direction of the plug position 11 b. The Securing elements 65 are formed from deformed areas of the fold-over layer 20a and extend in the direction of the plug-side end 3 into the latching tongue opening 59.

At the plug-side end 3 of the contact element 1 there is a head region S. In this, the multilayer region 9 is tapered in the insertion direction 2 such that a head width 67 is smaller than a connector width 69.

The head width 67 indicates the width of the head 21 along an axis 71 perpendicular to the insertion direction 2 and parallel to the Umschlaglagenebene 32.

The connector width 69 indicates the width of the contact element 1 in the multi-layer area 9 outside the head area S. The connector width 69 is measured parallel to the axis 71. The single-layer region 15 adjoins the reinforcement region V at the conductor-side end 5.

Fig. 6 shows the embodiment of Fig. 5 in a rear view.

The plug layer 1 1 b has the spacers 51, which keeps the fold-over layer 20 a at a distance from the plug layer 11 b and prevents undesired compression of the layers 11 b and 20 a. The spacers 51 are formed by punching or other suitable forming techniques in the connector layer 1 1 b. Both folded edges 47 abut against these spacers 51.

The securing elements 65 are hook-shaped. They are connected to the fold-over layer 20a, or extend from this. The securing elements 65 are first bent in the direction of the plug position 1 1 b and then point in the direction of the latching tongue 31st The securing elements 65 prevent a bending back of the latching tongue 31 in the contact element 1, so that the function of the latching tongue 31 is maintained.

FIGS. 7 and 8 show a third embodiment of a contact element 1 according to the invention. Here, FIG. 7 shows the embodiment in a perspective view and FIG. 8 shows the embodiment in a longitudinal section along the sectional plane AA drawn in FIG. 7. Like the second embodiment, the third embodiment has a multi-layered region 9 pointing in the plugging direction 2 and a reinforcing region V. Against the plugging direction 2, a crimping region C adjoins the reinforcing region V. The crimping area C points transverse to the longitudinal direction 43 standing crimping teeth 73, which serve for connection to foil conductors (not shown) or a cable (not shown). Between the crimping region C and the reinforcing region V, a bending portion B is disposed. The bending section B has bending regions 75, which can serve to align the plug-side part 3, when the contact element 1 is connected at its crimping region C to an electrical line.

As in the previously described embodiments, the multi-layer region 9 consists of two contact layers 1 1, which are parallel to each other with the exception of the head region S.

The contact element 1 has a spacer 23, which extends from the turnup 11 1 a in the direction of the gain region V. The spacer 23 is formed from a deformed edge 30 of the turnup layer 11a. The edge 30 extends transversely to the plug-in direction 2 and is arranged at an end of the turn-up ply 11a adjacent to the reinforcing region V. The spacer 23 is described in more detail with reference to FIGS. 9 and 10.

The contact element 1 has a latching tongue 31, which extends from the plug position 11 b outward against the plug-in direction 2. The latching tongue 31 projects through the fold-over layer 20a, which, like the plug-in layer 11b, has a latching tongue opening 59.

FIG. 9 shows an enlargement of the circle marked K in FIG. 8 about the spacer 23, and FIG. 10 shows a section along the sectional plane marked B-B in FIG. 9. The spacer 23 extends from the turnup 11 1 a starting against the insertion direction 2 in the direction of the conductor end 5. The spacer 23 has a support portion 77 and a Versetzungsabschnitt 79. In Versetzungsabschnitt 79, the contact material 4 of the turnup 11 1 a in the direction offset to the plug position 1 1 b out. The support region 77 is arranged at its end facing the conductor end 5 between the fold-over layer 20a and the plug layer 1 1 b. The support region 77 of the spacer 23 supports the fold-over layer 20a and the plug layer 1 1 b in the reinforcement region V from each other. Since the support portion 77 rests against the plug layer 1 1 b, and the envelope layer 1 1 a in the multi-layer area 9 is supported against the plug layer 1 1 b.

Between the plug layer 1 1 b and the Umfaltlage 20 a, the gap 81 extends. The width 83 of the intermediate space 81 is smaller than a thickness 85 of the contact material 4. In order to place the support area 77 between the fold-in area 17 at a predetermined plug-side cross-section 17. Läge 20a and the connector layer 1 1 b to order, the Umfaltlage 20a has two in the sectional plane BB triangular recesses 87. The recesses 87 can be made, for example, by pressing the corresponding portions of the fold over layer 20a. Alternatively, instead of the recesses 87 in the fold-over layer 20a, a recess may be located on the support region 77 so that it can be inserted between the fold-over layer 20a and the plug layer 11b. The recesses 87 extend substantially parallel to the fold-over layer 20a. They do not necessarily have to be triangular. The shape depends on the shape of the support portion 77. In the exemplary embodiment shown, the support region 77 is trapezoidal in the sectional plane BB, with the tip of the trapezoid pointing in the direction of the conductor-side end. The triangular recesses 87 are optimized for receiving the trapezoidal support region 77.

FIGS. 1 1 and 12 show a fourth embodiment of a contact element 1 according to the invention. 1 1 shows a perspective view and FIG. 12 shows a longitudinal section along the sectional plane indicated by A-A in FIG. 11. The fourth embodiment substantially corresponds to the third embodiment described above. Therefore, at this point, only the differences between the two embodiments are discussed.

The contact element 1 has a spacer 23, which extends as in the third embodiment of the turnup 11 1 a in the direction of the conductor-side end 5. However, the spacer 23 of the fourth exemplary embodiment has a securing section 89 at its end facing the conductor-side end 5. The spacer 23 and the securing portion 89 are described in detail with reference to FIGS. 13 and 14. The contact element 1 has a latching tongue 31, which corresponds to the latching tongue 31 of the second and the third embodiment. In order to avoid bending back of the latching tongue 31 in the direction of the plug-in position 1 1 b or by the latching tongue opening 59 in the plug-in position 1 1 b and the folded-over position 20 a, two latching tongue openings 59 extend from the plug-in position 1 1 b opposite fuse elements 65 present. The securing elements 65 are described in more detail with reference to FIG. 15.

FIGS. 13 and 14 show the details of a spacer 23 according to the invention of the fourth embodiment. In this case, FIG. 13 shows an enlargement of the circular section K marked in FIG. 12, and FIG. 14 shows a section along the sectional plane BB marked in FIG. The spacer 23 extends from the turn-up position 11a against the insertion direction 2 in the direction of the conductor-side end 5. The offset portion 79 displaces the contact material 4 from the turn-up position 11a between the connector layer 11b and the fold-over layer 20a. The support region 77 is located on the plug layer 1 1 b. As a result, the plug layer 1 1 b is supported against the turnup position 1 1 a. Likewise, the fold-over layer 20a bears against the support region 77 and is thereby supported against the plug layer 11b.

At the end facing away from the plug-in direction 2 of the spacer 23 is the securing portion 89. The securing portion 89 has securing wings 91 which extend outward from the plug position 1 1 b away. The folded-over layer 20a has a form-fitting opening 93 into which the securing wings 91 extend. The securing wings 91 thus form a positive connection with the fold-over layer 20a in the longitudinal direction 43. As a result, slippage of the turnup layer 1 1 a in the longitudinal direction 43 can be prevented. This is particularly advantageous when the contact element 1 is inserted into a counter contact element (not shown) or is released from it and between the contact element 1 and the Gegenkontaktele- ment a large force on the turnup 11 1 a and the connector layer 1 1 b acts.

To perform the spacer 23 with its support region 77 under the Umfaltlage 20a to the positive closure opening 93, the Umfaltlage 20a has a recess 87. The recess 87 can be made for example by pressing the contact material 4 of the Umfaltlage 20a in the area above the spacer 23. In order to facilitate the manufacture of the contact element 1 and to obtain some clearance between the edges of the securing wings 91 and the fold-over layer 20a, the edges 95 and 97 are rounded off. In this case, the curves of the leading edges 95 preferably have a smaller radius than the curves of the trailing edges 97. The leading edges 95 are less strongly rounded in order to increase the positive connection of the securing section 89 in the insertion direction 2 with the fold-over layer 20a. As a result, a slipping out of the spacer 23 from the intermediate space 81 is made more difficult. The trailing edges 97 are less rounded, as against the insertion direction in addition to the positive connection between the securing portion 89 and the edge 99 of the form-locking opening 93 is a positive connection between the turnup 11 1 a and the fold over 20a. The curves facilitate the assembly of the contact element 1 and prevent protruding sharp edges or tips of the contact element 1, in particular because the fuse wings 91 can protrude slightly from the positive connection opening 93, for example, after a load on the contact element 1. To bend the securing wings 91 during manufacturing in one direction From the plug position 1 1 b away, seen in the longitudinal direction 43 are seen between the securing wings 91 and the remaining spacer 23 two recesses 101st

15 shows a section through a contact element 1 according to the invention according to the fourth embodiment along the sectional plane indicated by CC in FIG. 11. The latching tongue 31 extends through the latching tongue opening 59 in the fold-over layer 20a and the plug-in layer 11b away from the plug-in layer 11b. The securing elements 65 close the locking tongue opening 59 in the plug position 1 1 b against undesired bending of the latching tongue 31 through the plug position 1 1 b. In a manufacturing step (not shown), the latching tongue 31, before it is bent, in a plane with the plug layer 1 1 b. In this case, it is connected to the securing elements 65. After a release of the latching tongue 31 and bending away from the plug position 1 1 b, the securing elements 65 are formed by pressing so that their distance 103 is smaller than the width 105 of the latching tongue 31st

LIST OF REFERENCE NUMBERS

1 contact element

2 plug-in direction

3 plug-side end

4 contact material

5 conductor end

7 envelope

9 multi-layered area

1 1 contact position

1 1 a transfer position

1 1 b connector position

12 open end

13 contact area

14 Outside

15 single layer area

16 outer contact layers

17 plug-side cross-section

19 conductor-side cross-section

20 reinforcement layer

20a fold over

21 head

23 spacers

24 reshaped area

27 closure element

28 assembled state

29 recess

30 reshaped edge

31 snap-in tongue

32 transhipment level

33 feet

35 locking tongue end

37 support element

39 surface

41 Surface of the contact area

43 longitudinal direction

45 envelope

46 Envelope direction

47 edges of the connector layer

49 plug-side end of the folding position

51 spacers

53 connection extensions

53a neck area

53b head area

53c deformation range

55 receiving opening

57 ladder-side end of the cover layer

59 latch opening

61 long side

63 conductor end of the locking tongue opening

65 security elements 7 head width 9 connector width

1 axis

3 crimping teeth

75 bending area

77 support area

79 dislocation section

81 gap

83 Width of the gap

85 thickness of the contact material

87 recess

89 Securing section

91 security wing

93 positive opening

95 leading edges

97 trailing edges

99 edge

101 recess

103 distance

105 locking tongue width

B bending section

C crimping area

S head area

V gain range

Claims

claims

Contact element (1) made of an electrically conductive contact material (4) for producing an electrically conductive connection, with a plug-side end (3) for mating with a complementary mating contact element, in particular a socket, and a conductor-side end (5) on which an electrical conductor can be fastened, wherein a plug-side cross-section (17) of the contact element (1) is greater than a ladder-side cross-section (19), characterized in that at the plug-side end (3) at least one envelope (7) of the contact material (4) is present.

Contact element (1) according to claim 1, characterized in that at the plug-side end (3) by the envelope (7) formed from at least two contact layers (1 1) formed multilayer region (9) of the contact material (4).

Contact element (1) according to claim 2, characterized in that at least one spacer (23) is provided, by which the at least two contact layers (1 1) are kept spaced from each other.

Contact element (1) according to claim 3, characterized in that the at least one spacer (23) is formed from at least one deformed region (24) of the contact material (4).

Contact element (1) according to one of Claims 3 to 4, characterized in that the at least one spacer (23) is formed from at least one deformed edge (30) of a contact layer (1 1) of the multilayer region (9), wherein the deformed edge (30) is adjacent to an adjacent contact layer (1 1).

Contact element (1) according to one of claims 2 to 5, wherein outer contact layers (16) of the multilayer region (9) are formed by contact layers (1 1), characterized in that extending from the plug-side end (3) in the direction of the conductor-side end ( 5) on the outer sides (14) of the outer contact layers (16) of the multilayer region (9) extends a continuous and smooth contact region (13) for repeated detachable connection with a complementary mating contact element.

Contact element (1) according to one of claims 2 to 6, characterized in that at least one of the contact layers (1 1) has at least one closure element (27) in an assembled state in at least one complementary recess (29) another contact position (1 1) of the multilayer area (9), in particular on a contact with a spacer (23) provided contact position (1 1), is positively received.

8. contact element (1) according to claim 7, characterized in that at least one closure element (27) with a corresponding recess (29) is frictionally pressed.

9. contact element (1) according to claim 7 or 8, characterized in that at least one closure element (27) and / or its associated recess (29) in the direction of the associated recess (29) is tapered.

10. Contact element (1) according to one of claims 1 to 9, characterized in that extending from the plug-side end (3) at least one projecting latching tongue (31) in the direction of the conductor-side end (5), wherein the latching tongue (31) at its Connector-side end has a foot (33) and at the conductor end a free locking tongue end (35).

1 1. Contact element (1) according to one of claims 1 to 10, characterized by at least one support element (37) which extends from the plug-side end (3) in the direction of the conductor-side end (5) and on the surface of an adjacent contact layer (1 1 ) is present.

12. Contact element (1) according to claim 1 1, characterized in that the at least one support element (37) with its conductor-side end in a region between the foot ß (33) and the free locking tongue end (35) of the latching tongue (31) on the Surface of an adjacent contact layer (1 1) is applied.

13. Contact element (1) according to one of claims 2 to 12, characterized by a reinforcing region (V) which extends behind the multilayer region (9) in the direction of the conductor-side end (5), wherein the reinforcing region (V) of at least two Reinforcing layers (20) is formed.

14. Contact element (1) according to claim 13, characterized in that the reinforcing region (V) has a further envelope (45) of the contact material (4), wherein the further envelope (45) by turning over the contact material (4) in another direction of reversal (46) is formed as the envelope (7) of the multilayer region (9) and the at least two reinforcement layers (20) are joined by the at least one further envelope (45).

15. Contact element (1) according to any one of claims 13 or 14, characterized in that at least one of the reinforcing layers (20) has at least one spacer (51) through which at least two of the reinforcing layers (20) are spaced from each other.

16. Contact element (1) according to any one of claims 13 to 15, characterized in that at least one of the reinforcing layers (20) with at least one of the contact layers (1 1) of the multilayer region (9) is connected directly or indirectly positively and / or frictionally ,

17. Contact element (1) according to any one of claims 13 to 16, characterized in that at least one of the reinforcing layers (20) of a latching tongue (31) which extends from another reinforcing layer (20) is penetrated.

18. Contact element (1) according to one of claims 13 to 17, characterized in that the reinforcing region (V) has at least one securing element (65) for preventing bending of the latching tongue (31) in the direction of the contact element (1).

19. Contact element (1) according to one of claims 1 to 18, characterized in that a head width (67) is smaller than a connector width (69).

20. Set comprising at least two contact elements (1) according to one of claims 3 to 12, characterized by spacers (23) of different dimensions.

21. Method for producing a contact element (1) according to Claim 1, characterized in that the contact material (4) is turned over at least once from the plug-side end (3) in the direction of the conductor-side end (5).