EP2987208A1

EP2987208A1 - Method for manufacturing plug-type contacts, plug-type contact and component assembly comprising at least one plug-type contact

Info

Publication number: EP2987208A1
Application number: EP14700671.2A
Authority: EP
Inventors: Thomas Betz
Original assignee: Walter Sohner & Co KG GmbH
Current assignee: Walter Sohner & Co KG GmbH
Priority date: 2013-04-16
Filing date: 2014-01-16
Publication date: 2016-02-24
Anticipated expiration: 2034-01-16
Also published as: WO2014170035A1; US10170852B2; US20160049743A1; ES2910451T3; EP2987208B1; DE102013103818A1

Abstract

The invention relates to a method for manufacturing plug-type contacts, in particular press-in contacts (100; 100a; 100b), comprising producing a rough contour, in particular a stamped contour, of a press-in contact (100; 100a; 100b), with a connecting body (1) and two limbs (21, 22) adjoining said connecting body, which limbs are arranged opposite one another, wherein the limbs (21, 22) have press-in regions (5) and end regions (4) remote from the connecting body (1) having contact sections (42, 44) which face one another and are spaced apart from one another in a defined manner; and reforming the limbs (21, 22), comprising moving the end regions (4) of the limbs (21, 22) towards one another with at least partial plastic deformation of at least one of the limbs (21, 22), wherein the contact sections (42, 44) of the limbs (21, 22) touch one another at least sectionally in a defined manner once the load has been relieved. The invention furthermore relates to a press-in contact (100; 100a; 100b) and to a component assembly comprising at least one contact receptacle (304) and one press-in contact (100; 100a; 100b).

Description

Method for the production of plug contacts, plug contact

and component arrangement with at least one plug contact

The present invention relates to a method for the production of plug contacts, in particular of press-fit contacts, which have a connection body and two adjoining legs which define a press-in area for receiving in a contact. The invention furthermore relates to a corresponding plug-in contact, in particular a press-fit contact, and to a component arrangement having at least one such plug contact, in particular a press-fit contact.

A press-in contact and a method for producing a press-fit are known from WO 2005 122 337 A1. The known press-in contact comprises a contact body and two legs formed integrally therewith, which are formed by chipless machining, wherein a separating operation and a widening is provided to form a press-fit. The two legs form a point, in which a separating gap is provided.

Similarly, DE 202 18 295 U1 discloses a contact element for printed circuit boards, with a specific for pressing into a bore of the printed circuit board pin part having two approximately parallel arms which are formed in pairs against a restoring force to each other movable.

Press-in connections, in particular press-fit contacts, of the general type are well known in the art and are particularly suitable for the production of electrical contacts with low contact resistance. The connections can be made quickly and inexpensively and - provided they are designed correctly, manufactured and assembled - can ensure high reliability and durability. It is known to provide Einpresskontakte with deformable shape elements that deform as defined as possible during assembly of the contact and should provide a certain contact force or holding force.

By press-in connections can be, for example, cohesive methods, such as solder joints, at least partially substituted. Typically, press-fit connections can be produced to form both a traction component and a form-fitting component. At the press-in contact and / or the associated contact-making, at least minimal deformations can result, which can contribute to an increase in the holding force and an increase in the contact area.

However, it has been shown that known press-fit contacts may have production-related tolerance fluctuations, which in turn can be reflected in large variations in assembly forces and / or contact forces of the joined compounds. On the one hand, this can lead to the fact that a sufficiently large contact force can not be generated, so that the desired reliability of the connection is not given. Furthermore, in this constellation, an increased contact resistance and / or result in a reduced contact area between the press-fit and a contact.

In the opposite case, that is, when an impermissibly high joining force for mounting the press-in contact is required, which can also lead to an increased contact force, component damage may result during assembly of the press-in connections. Again, this can degrade the reliability and lifetime of the connection. The disadvantages described above are all the clearer the higher the tolerance requirements for the press-fit connections. However, increased tolerances may be required in order to be able to achieve, for example, miniaturization and / or an increase in the packing density, that is to say the number of connections per unit area. Such requirements may arise, for example, in the field of vehicle technology, in particular electromobility, in which high currents often flow in order to transmit large powers at comparatively low voltage levels.

Against this background, the invention has for its object to provide a method as economical as possible for the production of plug contacts, which ensure a high reproducibility and tolerance tolerance and simplify the installation of the plug contacts as possible. Furthermore, a plug-in contact is to be provided which can be produced as economically as possible with a high degree of tolerance and with which it is possible in a simple manner to produce as precisely reproducible press-fit connections as possible.

This object is achieved by a method for producing plug contacts with the following steps:

- Generating a raw contour, in particular a punched contour, one

Plug contact, with a connecting body and two adjoining legs, which are arranged opposite to each other, wherein the legs press-in areas and the connection body have opposite end portions with contact portions facing each other and defined spaced from each other; and

- Forming the legs, comprising moving toward each other of the end portions of the legs under at least partial plastic deformation of at least one of the legs, wherein touching the contact portions of the legs after a relief at least partially defined.

The object of the invention is completely solved in this way.

According to the invention, namely, on the one hand, the rough contour can be generated particularly easily, since the contact portions of the two legs can be sufficiently spaced from each other. This allows about the use of relatively simple designed robust cutting tools or punching tools. The additional forming process, which takes place before the assembly of the plug-in contact, makes it possible in a simple manner to be able to manufacture the plug-in contacts with high precision with close tolerances. Namely, by the forming process is designed such that touch the contact portions of the legs after forming, large tolerance variations, which are usually associated with "free" forming operations, avoid. A "free" forming process is to be understood here as meaning, for example, a production step in which the legs are deformed such that a geometrically determinable gap, that is to say a defined gap, then results between their contact sections.

Of course, it would be much more complex to generate a defined gap between the two legs, as these defined to bring together to plant. In this way, the final shape of the plug-in contact is highly accurate reproducible. Accordingly, significantly reduced fluctuations in the assembly force or the press-in force and the contact force of the joined press-in connection can result. The process reliability in the production of corresponding press-in connections can increase significantly. Transition resistances resulting from the press-fit connection are subject to less fluctuation. Compared to press-in contacts, in which the end portions of the legs are designed to be continuous, so are integrally connected or cohesively with each other, resulting in a plug contact, which is provided with legs having separate contact portions, however, touch the sections defined , in mounting further advantages. During joining, ie during the production of the press-in connection, the contact sections of the legs can namely roll over one another in a defined manner as a result of the deformation of the legs. In other words, during the joining process, a contact surface between the contact sections may change, in particular increase. In this way, the elasticity or resilience of the plug contact can increase during the press-fitting process, so that the production of the press-fit connection can be simpler and with greater accuracy. This is especially true in comparison to press-in contacts, in which the end portions of the legs are rigidly and firmly connected.

In other words, a plug-in contact made in accordance with the aforementioned method can have the advantages of press-fit contacts with legs having spaced apart contact portions (high elasticity) and the advantages of press-fit contacts having legs whose end portions are rigidly connected together are (high accuracy, small shape deviations) combine, without having to accept the respective specific disadvantages.

The reshaping of the legs can be carried out such that both legs are moved simultaneously or laterally offset from each other to contact the contact portions with each other. In principle, however, it would also be conceivable to reshape only one of the two legs in order to establish the contact between the legs. Accordingly, the term "moving toward one another" should generally be understood to mean a relative movement directed towards one another between the end regions of the legs.

The contact portions may be formed in particular as mutually facing contact surfaces on the legs. After the legs have been reshaped, a continuous tip can emerge at the plug-in contact. areas of both legs is formed and in particular has no gap or no gap.

The rough contour may in particular be a semi-finished product of a flat material or strip material with a substantially flat extension. In principle, conductive materials, in particular metals, are suitable. The rough contour can be generated by way of example by means of a cutting process. This punching operations and / or fineblanking operations can be used. In general, chipless separation processes are suitable for producing the raw contour.

The plug contact can in principle be assigned to a further component, so be connected in one piece with this. It can be a power connection, such as a busbar. In particular, a plurality of plug contacts may be formed at the same time on a component. These can be produced simultaneously by way of example with a multiple tool. However, it would also be conceivable to manufacture a plurality of plug contacts on a component in succession.

Preferably, the plug contact is designed as a press-in contact.

In an advantageous embodiment of the method, the plastic deformation during forming is introduced such that the contact portions of the legs are biased after forming with a contact force against each other.

By this measure can be achieved that the contact portions of the legs not only at least partially touch, but even act with a force on each other. In this way, the production of press-fit contacts can be carried out particularly reliable, since even with possible fluctuations in the contact force is always a contact between the contact sections is guaranteed. In other words, a geometric requirement (the contacting) can be replaced by a requirement of a certain force (the contact force), with sufficiently large tolerances being allowed with respect to the contact force. Even with large tolerance fluctuations, however, the geometric requirement can always be met. According to a further embodiment, the deformation of the legs takes place to form an inner contour, which allows a flexibility of the legs during assembly of the press-fit.

Even if the legs are rigidly connected to each other at their end facing the connector body and in their end portions facing away from the terminal body contact portions which touch each other, a deformable yielding region can result between the ends. The inner contour can in particular be an inner recess which is bounded by inner sides of both legs. This design also contributes to increasing the elasticity of the press-fit.

In a preferred embodiment of the method, the reshaping of the legs further comprises a lateral deflection of at least one of the legs, wherein at least the contact portions of the legs are laterally offset in a deflected position to each other.

For the purposes of this application is meant by the "lateral deflection" an at least partial displacement of the at least one leg having at least one movement component which is directed perpendicular to a planar extension of the press-fit. Usually, the planar extent of the press-in contact can coincide with the planar extent of the flat material from which the press-fit contacts are made.

In other words, the legs may be arranged approximately such that inner sides of the legs are facing each other, while outer sides of the legs are facing away from each other. In addition to the inner sides and the outer sides of the legs may also be provided lateral sides, wherein the lateral sides of the two legs are arranged at least in the non-deflected state in a plane which is defined by a flat side of the semifinished product. It has been shown that can result from the lateral deflection of the at least one leg during forming open spaces and movement possibilities that are certainly not given, if both legs remain arranged in their initial position and its output plane.

In an advantageous embodiment of this embodiment, both legs are deflected laterally in opposite directions. Thus, both legs, in particular their contact portions can be offset by a measure to each other, resulting from both lateral movements. For example, starting from an imaginary lateral neutral position, which corresponds, for example, to a median plane through the press-in contact which coincides with its longitudinal extension, a first lateral direction and a second lateral direction may arise, which is opposite to the first lateral direction. It is preferred if both legs are deflected laterally such that their contact portions are offset from one another in the direction of the longitudinal extent of the press-in contact such that no overlap exists between them.

It is also particularly preferred if the contact portions of the legs are moved toward each other during the forming and at least partially past each other. In other words, the laterally deflected or disengaged legs may be initially moved toward each other but, moreover, may be moved beyond a position due to the offset, in which contact would occur between the contact portions in the undeflected or disengaged state. The contact portions of the legs can be laterally moved past each other at least partially.

The lateral disengagement of the legs and the at least partially Aneinandervorbeibewegen the legs may be components of a combined movement, so at least partially (time) run parallel. However, it is also conceivable to let the movements mentioned follow one another in chronological succession. The movement toward one another and the at least sectionwise moving apart of the legs can take place substantially perpendicular to the deflection movement of the legs. The said measure has the significant advantage that at least one the leg, preferably both legs, can be plastically deformed such that, after being transferred to the lateral starting position, that is to say the lateral neutral position, the contact between the contact sections can be reliably produced and, in particular, a prestress between the contact sections can exist. Such a deformation to generate the force could be generated without the lateral disengagement of the legs only with increased effort, since the contact portions of the legs would rather touch and therefore would not allow further deformation entry.

Thus, by a defined "overstretching" of the limbs, a secure abutment or contact between them can be generated in a simple manner, without excessive demands on accuracy being made on the deformation.

According to a further embodiment of the method, the lateral deflection takes place substantially under elastic deformation of the legs. This measure has the particular advantage that, after the forming process, the legs, to a certain extent, automatically push back into their lateral neutral position. Thus, it is conceivable that the (at least in sections) past each other and plastically deformed legs or their contact portions are moved back against this movement entry until the lateral overlap between them is repealed. Then the thighs can return by themselves to their neutral position

"Snap".

According to a further aspect, the lateral deflection is at least partially under plastic deformation of the legs, wherein the forming further comprises a lateral counter-movement of the two legs, whereby the contact portions of the legs are converted into a lateral neutral position.

According to this embodiment, the legs experience at least partially a plastic deformation in the lateral direction. Thus, it is conceivable that the legs can not "snap" back into the lateral neutral position by itself. In this case, another lateral deflection can be made, the original one lateral deflection is in the opposite direction, in turn to bring about a plastic deformation of the legs, which compensates for the previously generated (lateral) deformation. In this way, the legs can be safely returned to their lateral neutral position, wherein the contact portions due to the introduced bias at least partially touch. Overall, it is preferred if the press-in contact retains its substantially flat basic shape even after forming.

According to a further embodiment, the two legs are punched and formed in such a way that results in a substantially almond-shaped configuration of the legs, wherein the two legs are preferably designed substantially mirror-symmetrical and in particular have a convexly outwardly projecting portion.

The outwardly protruding portions may act in particular as the press-in areas, which make contact in the joined state of the press-in contact for making contact. The design of both opposing legs may generally comprise an oval or elliptical shape. The almond-shaped configuration can be characterized in particular by a pointed end, which is defined by the end regions of the legs. The end facing away from the pointed end may be defined and rounded by a transition between the two legs and the connecting body. Also this end can basically be designed pointed. In particular, the resulting between the legs interior can be designed substantially almond-shaped and taper in the region of the contact portions and be provided in the region of the connecting body with a fillet or groove.

In an advantageous embodiment, an inside transition between the press-in area and the contact portion of the legs is provided with a rounding. It is particularly appropriate to let the areas tangentially into each other. Preferably, no angular transitions are present. By way of example, the press-fit region of the limbs can be configured essentially concave on the inside, with a convex transition connecting to the contact section. In this way, in particular when joining the press-fit optimal deformability the thigh result. When compressing or compressing the two legs whose contact portions can roll on each other. In this way unfavorable voltage curves can be avoided, which could possibly lead to component damage.

In an advantageous embodiment of this embodiment, the two legs are provided with press-in areas, which have a substantially convex outer contour and a substantially concave inner contour, wherein there is a substantially almond-shaped inner recess between the opposite legs.

Thus, it is preferred according to a further embodiment, when the legs are configured continuously curved and in particular in their longitudinal extension have no straight sections. The advantageous design of the legs can be effected substantially already by the generation of a correspondingly shaped rough contour. Alternatively or additionally, curved regions of the legs can also be generated and / or varied by the deformation of the legs.

In an advantageous embodiment, at least the connecting body or the legs are at least partially impressed. The embossing may in particular be aimed at smoothing or rounding punching edges, burrs or the like. On the one hand, this can help to avoid voltage peaks that could result during reshaping of the legs. Furthermore, an enlargement of the potential contact surface with the contact in the joined state can be effected.

In the embossing or embossing may be a manufacturing step, which follows about a punching or cutting process and is upstream of the step of forming. Again, it is advantageous if there is a sufficiently large gap between the contact portions of the legs. In principle, it is also conceivable to combine the cutting process for producing the rough contour and the embossing process for smoothing or rounding edges. According to a further development of the method, the production of the raw contour further comprises creating a concave constriction at the transition between a press-in area and a connection area, wherein the concave constriction is formed by curved sections of the legs. This configuration can yield favorable force profiles when forming or joining the press-fit.

The object of the invention is further achieved by a plug contact, in particular a stamped plug contact for generating an electrical connection, with a connecting body and two adjoining curved legs, wherein the connecting body and the legs are designed in one piece, each leg having a Pressing in and having an end portion with a contact portion, wherein both legs define a substantially almond-shaped inner contour, and wherein the contact portions of both legs are facing each other and touching each other at least partially defined.

Also in this way the object of the invention is completely solved.

In principle, the inner contour may also be configured as a gusset or as a ball-and-pinion. In particular, in the direction of the connection body, the inner contour between the legs may have a fillet or groove. In general, the inner contour can be egg-shaped, elliptical or oval. Preferably, both legs are designed mirror-symmetrically to each other.

Preferably, the plug contact is formed as a press-in contact, in particular as a stamped press-fit.

Such a press-fit is particularly suitable for the transmission of high currents. The press-in contact can provide a sufficiently low contact resistance. It is particularly preferred if the press-fit contact is manufactured according to one of the aspects of the aforementioned method. In a preferred embodiment of the press-in contact, the contact portions of both legs are biased against each other with a contact force. In this way it is ensured that there is a contact between the contact portions of the legs. Thus, a highly accurate design can be ensured with low tolerances.

According to a further development of the press-in contact, the legs have a connection region for connection to the connection body, the legs having a concave constriction at a transition between the press-fit region and the connection region, which is formed by curved sections of the legs at their ends facing the connector body have an internal rounding, which merges into the interior, and wherein the concave constriction of the legs defines a constriction between the interior and the rounding. At the bottleneck, the limbs can touch in defined fashion when forming or joining the press-fit contact. The connection area can be relieved by the inner rounding.

A press-fit contact according to one of said aspects is preferably used in a component arrangement, which further comprises at least one contact receiving and at least one such press-in contact, wherein the press-in contact is received under pretension in the contact receptacle.

It is understood that the features of the invention to be explained below and those to be explained below can be used not only in the respectively specified combination but also in other combinations or in isolation, without departing from the scope of the present invention.

Further features and advantages of the invention will become apparent from the following description of several preferred embodiments with reference to the drawings. Show it: 1 a shows a rough contour of a press-fit contact with two opposing legs in a schematically illustrated plan view;

1 b is a schematically illustrated front view of the rough contour of the press-fit contact according to FIG. 1 a;

FIG. 2a is a schematic plan view of an embossed press-fit contact based on the rough contour shown in FIG. 1a; FIG.

2b shows a schematically illustrated front view of the embossed press-fit contact according to FIG. 2a;

Fig. 3a is a schematically illustrated plan view of a press-fit according to

FIG. 2a in a deformed state in which legs of the press-in contact touch in sections; FIG.

FIG. 3b shows a schematically illustrated front view of the press-fit contact according to FIG. 3a; FIG.

Fig. 4a is a schematically illustrated plan view of a raw contour of another

Press-fit contact with two opposite legs;

FIG. 4b is a front view, schematically represented, of the rough contour of the press-fit contact according to FIG. 4a; FIG.

5a shows a schematically illustrated plan view of a press-fit contact according to the blank contour shown in FIG. 4a in an embossed state;

5b shows a schematically illustrated front view of the press-fit contact according to FIG. 5a; 6a shows a schematically illustrated plan view of a press-fit contact according to FIG. 5a with laterally disengaged legs;

FIG. 6b shows a schematically illustrated front view of the press-fit contact according to FIG. 6a; FIG.

Fig. 7a is a schematically illustrated plan view of a press-fit according to

FIG. 6a with legs deformed in a longitudinal direction; FIG.

FIG. 7b shows a schematically illustrated front view of the press-fit contact according to FIG. 7a; FIG.

8a shows a schematically illustrated plan view of a press-fit contact according to FIG

FIG. 7a with legs fed back into a lateral neutral position, which contact each other at least in sections; FIG.

8b shows a schematically illustrated front view of the press-fit contact according to FIG. 8a;

9 is a diagrammatically illustrated illustration of a sequence of lateral positions of the legs of a press-fit contact according to FIGS. 4a to 8b;

10a shows a schematically illustrated plan view of a further press-in contact with two legs which touch each other at least in sections;

10b shows a schematically illustrated front view of the press-fit contact according to FIG. 10a;

Fig. 1 1 is a simplified schematic view of a busbar with a

Plurality of press-fit contacts; FIG. 12 shows a detail view of a section of the illustration shown in FIG. 11; FIG.

13 shows a perspective view of a board element with a plurality of contact receptacles for press-fit contacts;

FIG. 14 a shows a schematically illustrated plan view of a further embodiment of a press-fit contact in a deformed state;

FIG. 14b shows a diagrammatically illustrated front view of the press-fit contact according to FIG. 14a; FIG. and

15 shows a schematically greatly simplified flow diagram of a method for producing press-fit contacts.

Various states of a press-fit contact 100 according to an exemplary embodiment during the manufacturing process are illustrated with reference to FIGS. 1 a to 3 b.

The press-fit contact 100 may for example be associated with a contact component, such as a busbar, cf. FIG. 1 1. In particular, a plurality of press-fit contacts 100 may be provided on a contact component. It is therefore understood that in particular the embodiments illustrated in FIGS. 1 a to 10 b may contain only partial representations.

1 a and 1 b illustrate a rough contour of the press-fit contact 100. The rough contour may in particular be a punched contour or a sectional contour, which is produced from a substantially flat semi-finished product. The press-fit contact 100 has a connection body 1, from which two legs or leg elements 21, 22 extend. The connecting body 1 and the legs 21, 22 are preferably made in one piece and in particular integrally connected to a component. The connection contour to this component is through the connector body. 1 provided. The legs 21, 22 are configured essentially mirror-symmetrically. The legs 21, 22 have an elongated extension and are approximately U-shaped or V-shaped aligned with each other. Between their ends, which merge into the connecting body 1, the legs 21, 22 include a transition 7, which may also be referred to as a gusset. The transition 7 may be designed in particular as a rounding or groove 7. The connection between the legs 21, 22 and the connection body 1 takes place essentially in a connection region 6.

Preferably, the press-in contact 100 is formed of a metallic conductive material. This may in particular be a plate-shaped or band-shaped semi-finished product, which is designed essentially as a flat material. It is preferred if the press-fit contact 100 is formed from a stampable or cuttable material. By way of example, this may be a material of thickness d, see also FIG. 1 b. Thus, the terminal body 1 and the legs 21, 22 may have substantially the same thickness d. The legs 21, 22 may further have a width b. Along their longitudinal extension, the leg elements 21, 22 may have substantially rectangular cross-sections according to the rough shape illustrated in FIG. 1a. In principle, it is conceivable to also execute the legs 21, 22 with substantially square cross sections. However, in particular due to the punching process or cutting process, changes in shape may also result in the legs 21, 22, so that also cross sections which deviate from the rectangular shape are conceivable.

The intermediate state of a press-fit contact 100 'illustrated in FIGS. 2 a and 2 b differs from the raw state of the press-fit contact 100 shown in FIGS. 1 a and 1 b essentially in that a smoothing and / or rounding of at least some of the edges the rough contour is done. Such an operation can be done in particular by means of embossing. The embossing can be combined with a punching and / or cutting process. The smoothing and / or rounding of edges, in particular of cutting edges or punched edges, can help to avoid voltage peaks, which may result in subsequent forming operations and / or in the joining of the press-fit contact 100 under certain circumstances. Furthermore, about the risk of Injuries in the manual handling of the press-fit contact 100 are reduced.

Each of the legs 21, 22 further includes an end portion 4 which faces away from the terminal body 1. In the end region 4 of the legs 21, 22 contact portions 42, 44 may be provided. The leg 21 may be the contact section 42. The leg 22 may be the contact portion 44. In the manufacturing stage illustrated in FIGS. 2a and 2b, the contact portions 42, 44 of the legs 21, 22 are clearly spaced from each other. A minimum distance between the contact sections 42, 44 can be defined, for example, by a minimum wall thickness of a punching tool or cutting tool with which the rough contour of the press-fit contact 100 is produced. According to the basic configuration shown in FIGS. 1 a and 1 b, the legs 21, 22 define therebetween a gap 10 which, however, is not surrounded by a closed contour, since (initially) there is no contact between the contact sections 42, 44.

3a and 3b illustrate a further manufacturing stage, in which the legs 21, 22 are moved towards each other so that the contact portions 42, 44 (see FIG. 2a) touch at least in sections. In this way, the legs 21, 22 together form a tip 3, which is closed. In other words, the closed tip 3 has no gap or gap. To produce the contacting, the contact sections 42, 44, at least one of the contact sections 42, 44, can be moved toward one another in a longitudinal direction, compare with arrows 46, 48 in FIG. 2b. By producing a plastic deformation at least in one of the legs 21, 22, the state of the press-fit contact 100 "shown in FIG. 3 a can be kept stable.

By closing the legs 21, 22 of the gap 10 can be converted into an inner contour or an interior 9, which now has a closed boundary. In general, the interior 9 has an elongated extension and is substantially oval, elliptical or designed as a gusset or ball dome. The interior 9 can in particular at its end facing the connector body 1 with the rounding 7 and at its end facing away from the connector body 1 with be provided a tip 8. Overall, the interior 9 can be designed almond-shaped. The legs 21, 22 may each have an insertion region 5 between their end regions 4 and the attachment regions 6. The press-in area 5 of each leg 21, 22 may be curved convexly outwardly according to the view shown in Fig. 3a. In the closed state of the legs 21, 22, a leg dimension or a width B can result overall in the press-in areas 5, cf. FIG. 3b. The leg dimension B must be adapted in a special way to a dimension of contact to be able to provide a secure press-fit. Therefore, it would be advantageous to be able to produce the leg dimension B with high reproducibility and the lowest possible tolerances. By the legs 21, 22 are transformed such that their end portions 42, 44 at least partially touch, the leg dimension B can be determined with high accuracy. However, various advantages resulting from the design of the press-fit contact 100 "as press-fit contact with" separate "legs 21, 22 can be maintained.

A further advantageous embodiment of the method and a resulting press-fit contact 100a are illustrated with reference to FIGS. 4a to 8b.

FIGS. 4a, 4b, 5a and 5b may correspond substantially to FIGS. 1a, 1b, 2a and 2b. FIGS. 4a and 4b show a press-fit contact 100a in the raw state, that is to say as a punched blank. The press-fit contact 100a has, in a known manner, a connection body 1 and two adjoining limbs 21, 22. The legs 21, 22 have a substantially V-shaped or U-shaped arrangement. The press-fit contact 100a can be punched by way of example from a semi-finished product of thickness d (see FIG. 4b).

5a and 5b illustrate a press-fit contact 100a 'which is based on the press-fit contact 100a according to FIG. 4a and furthermore has rounded or smooth edges and ridges. The rounding or smoothing of the press-fit contact 100a 'can be generated in particular by means of impressions. The legs 21, 22 may define in a known manner an (open) gap 10 between them. FIGS. 6a and 6b illustrate a deformation step in which the legs 21, The deflected legs are designated 21 'and 22' in Fig. 6b The lateral deflection may be in the direction of arrows indicated 50 and 52 in Fig. 6b Essentially limited to contact portions 42, 44 of the legs 21, 22.

In other words, in the connection region 6, for example, the legs 21, 22 may at most only have an extremely small lateral deflection. The arrows 50, 52 in Fig. 6b exemplarily illustrate a (lateral) direction which is oriented substantially perpendicular to a median plane or neutral plane through the press-fit contact 100a ". It is preferred if the legs 21 ', 22' are deflected so far laterally This state is shown in Fig. 6b, the lateral deflection can basically be purely elastic, but it is also conceivable that the legs 21 ', 22' are at least deflected laterally sometimes also plastically deform.

Based on the position shown in Fig. 6b, the legs 21 ', 22' can be advantageously deformed against each other in a particular manner to allow a state in which the contact portions 42, 44 at least partially contact each other to form a bias. Such an operation is illustrated by Figs. 7a and 7b. FIG. 7b shows that the legs 21 ", 22" can be moved towards one another starting from the position shown in FIG. 6b. This movement (also:

Longitudinal movement) is illustrated in FIG. 7b by arrows designated by 46, 48. It can also be seen from FIG. 7b that the legs 21 ", 22" can not only be moved toward one another but at least partially past each other, at least in the region of their contact sections 42, 44. Even if, according to the representation of a press-fit contact 100a '"as shown in FIG. 7a, a contact between the contact sections 42, 44 apparently occurs, a relative movement of the legs 21", 22 "beyond this state is made possible.

This is particularly advantageous because in this way a plastic deformation of the legs 21 ", 22" can be generated, which can then provide a biasing force when the legs 21 ", 22" are returned to their neutral position. In other words, the movement of the legs 21 ", 22" is not by a stop limited, which would be given by the contact of the contact portions 42, 44, when the contact portions 42, 44 do not overlap laterally. The legs 21 ", 22" can thus be "overstretched" in the longitudinal direction (arrows 46, 58). Should it then come to a relief of the legs 21 ", 22", it would be conceivable that they remain in a mutually at least partially overlapping position in the side disengaged state.

Figs. 8a and 8b illustrate a state of a press-fit contact 100a "" based on the state of Figs. 7a and 7b, but with the legs, and in particular their contact portions 42, 44, returned to their (lateral) neutral position are, compare reference numerals 21 "', 22"' in Fig. 8b. On the other hand, this can take place by utilizing a (lateral) elastic restoring force of the legs 21 "', 22"'. If, however, in the lateral disengagement illustrated in FIGS. 6a and 6b, a plastic deformation of the legs 21 "', 22"' in the lateral direction has occurred, then a counter-directional plastic deformation can reach the neutral state of the legs 21 shown in FIG. 8b '', 22 "'effect. Nevertheless, the contact portions 42, 44 defined to form a biasing force F come to rest with each other. The biasing force F can be defined in particular by targeted overstretching of the legs 21 "', 22"', see also Fig. 7b. Analogous to the state shown in FIG. 3a, the press-fit contact 100a "" can result in a press-in region 5 which, due to the defined contact between the contact sections 42, 44, results in a leg dimension B (see FIG. 8b) which has low tolerances and high precision is reproducible.

In particular, the step of lateral disengagement illustrated in FIGS. 6a and 6b permits a significant deformation of the legs 21, 22 of the press-fit contact 100a. Thus, residual stresses in the material of the press-fit 100a can be selectively generated and used to improve its dimensional accuracy and reliability. It is understood that in particular the steps shown in FIGS. 6a to 7b of the lateral disengagement and the movement of the legs 21, 22 relative to one another can take place as a result of a combined movement. The steps can basically be performed simultaneously, but also with a time lag. As already mentioned above, it is preferred if both legs 21, 22 are deflected and deformed in a symmetrical manner. In principle, however, it is also conceivable merely to move one of the two legs 21, 22 in a corresponding manner and to deform.

Fig. 9 shows, for illustrative purposes only, a superimposition of various states of the press-fit contact 100a, which correspond approximately to the positions shown in Figs. 5b to 8b. A lateral neutral plane or plane of symmetry of the press-fit contact 100a or the semifinished product used for its manufacture is indicated at 60. In Fig. 9, the press-in contact 100a is shown tilted slightly to make even in the neutral position despite symmetrical design of the legs 21, 22 both of the legs 21, 22 visible.

In the stamped and optionally embossed state, the legs 21, 22 (laterally) are in their neutral position. In a further step, which is also illustrated with reference to FIGS. 6a and 6b, a lateral disengagement of the legs takes place, compare the reference numerals 21 ', 22', in the direction of the arrows designated by 50 and 52. In this disengaged state, the legs can be deformed in the longitudinal direction relative to one another, compare the reference numerals 21 ", 22". This can be done according to the orientation shown in FIG. 9 approximately substantially perpendicular to the local plane of view. In this way, a plastic deformation of the legs 21 ", 22" take place, which can be used to generate a bias voltage. Subsequently, the legs can be returned to their neutral position with respect to the neutral plane 60, see the reference numerals 21 "'and 22"'. This can be done along arrows labeled 50 ', 52'. The return of the legs 21 "', 22"' can basically be done by taking advantage of their inherent elasticity. Alternatively or additionally, however, it is also conceivable to bring about the return of the legs 21 "', 22"' by a plastic deformation.

A further advantageous embodiment of a press-fit contact 100b is illustrated with reference to FIGS. 10a and 10b. In a known manner, the press-fit contact 100b has a connection region 1 and two adjoining limbs 21, 22, which are configured substantially symmetrically with respect to one another. The legs 21, 22 are connected in a connection region 6 to the connection body 1. At their terminal body 4 facing away from the connecting body 1, the legs 21, 22 contact portions 42, 44 which at least partially contact each other, in particular to form a biasing force. In this way, the contact portions 42, 44 of the legs 21, 22 form a closed tip 3. In order to generate the configuration shown in FIG. 10a, the method illustrated according to FIGS. 4a to 8b may be used.

Between the end region 4 and the connection region 6, the legs 21, 22 can define a press-in region 5, in which a leg dimension B results, see also FIG. 10b. Between the legs 21, 22, an inner contour or a (closed) interior 9 can result, which is approximately almond-shaped. In the direction of the connecting body 1, the interior 9 may have a rounded end or a groove 7. In the direction of the tip 3, the interior 9 can have a pointed end 8.

In contrast to the press-fit contacts 100 and 100a described above, the press-fit contact 100b has a substantially continuous curved configuration of the legs 21, 22. In particular, the legs 21, 22 of the press-fit contact 100b are designed in their longitudinal extent substantially without straight sections. By way of example, the leg 22 indicates a leg radius denoted by R, which extends over substantial regions of the leg 22, at least over the press-in region 5. A targeted adaptation of the leg radius R allows an optimization of an insertion force or joining force during assembly of the press-fit contact 100b as well as an optimization of the contact surface of the press-fit 100b when contacting a contact, such as a receiving socket. In this case, it is advantageous if a back of the press-fit contact 100b lies as flat as possible against a corresponding contact receptacle.

Furthermore, the leg 22 has an inner transition radius designated by r, which describes a transition between the press-in region 5 and the end region 4, in particular its contact portion 44. A suitable design of the transition radius r allows a targeted deformation of the legs 21, 22 of the press-fit 100b during insertion into a contact. In particular, the transition radii r of both legs 21, 22 can nestle against each other when the Press-in area 5 of the legs 21, 22 is pressed together during joining. It can therefore result in the press-fit contact 100b according to FIG. 10a, an interior 9, the connecting body 1 facing fillet 7 merges into a concave fillet, which extends substantially over at least the press-in region 5, wherein it adjoins the convex transition radius r, the pointed towards the tip 3 of the injection body 100b.

The press-fit contacts 100, 100a and 100b described above can be used, for example, in vehicle construction or in similar application areas in which high currents flow. Conventional dimensions for the thickness d of the semifinished product (see FIG. 1 b) can be approximately in the range of a few tenths of a millimeter up to a few millimeters. It can give a leg dimension B, which is about 2.5 x d to 4 x d. The legs 21, 22 may have a width b perpendicular to the thickness d, which lies in similar orders of magnitude as the thickness d. In principle, the legs 21, 22 may have a square cross-section. However, it is also conceivable that the thickness d is greater than the width b. Conversely, it is conceivable that the thickness d is smaller than the width b. It is preferred if the lateral deflection of the legs 21, 22 at least in the region of the contact portions 42, 44 causes an offset which is greater than or equal to the thickness d. In particular, when the offset is greater than the thickness d, the legs 21, 22 can be guided past each other.

It is understood, however, that also configurations of the press-fit contacts 100, 100a, 100b and of the press-fit contact 100c, which is illustrated below with reference to FIGS. 14a and 14b, are conceivable which deviate from the dimensions described above.

FIGS. 11 and 12 illustrate, by way of example, a bus bar 302, which is shown as representative of a multiplicity of conceivable contact components. By way of example, the busbar 302 has five contact elements 100, one of which is shown enlarged in sections in FIG. 12, see detail X. By means of a plurality of press-fit contacts 100, a kind of parallel contacting can take place in order to be able to transmit particularly high currents. In this way, about several hundred amps can be transmitted. It is preferred if the in Fig. 1 1 shown busbar 302 and all recorded there pressfit contacts 100 are integrally formed.

Fig. 13 illustrates a board element 301, which has a plurality of contact receptacles 304, in particular of receiving sockets. Typically, the contact elements 304 may be holes or similar shape elements. The contact receptacles 304 may be metallized and / or have metallic inserts. The board element 301 may be adapted to the busbar 302 and provide about five corresponding contact receptacles 304 in order to be able to receive the five press-fit contacts 100 of the busbar 302 in a joined state.

A further advantageous embodiment of the method and a resulting press-fit contact 100c are illustrated with reference to FIGS. 14a and 14b. In principle, the press-fit contact 100c can be produced analogously to the press-fit contacts 100, 100a, 100b using the production steps described above. In particular, the legs 21, 22 of the press-fit contact 100c can be pretensioned in the manner described above, so as to touch each other at least in sections in the region of their contact sections 42, 44 after a forming process.

The press-fit contact 100c is characterized in particular with regard to the design of the transition between the press-in region 5 and the connection region 6 by a modified embodiment of the legs 21, 22. The legs may be provided between the connection body 1 associated rounding 7 and the interior or the inner contour 9 with a constriction 68, which is formed by curved portions 70, 72. The leg 21 has a curved portion 70 is provided. The leg 22 has a curved portion 72 is provided. The curved portions 70, 72 may be substantially convex on their sides facing each other and substantially concave on their sides facing away from each other. An arrow designated R in Fig. 14a denotes a concave curvature of the portion 72 at the leg 22. Thus, each of the legs 21, 22 is an S-shaped Have shape. The transition between the interior 9 and the rounding 7 of the press-fit contact 100c may accordingly comprise a bottleneck.

This contour of the press-fit contact 100c can be generated in particular as a rough contour, for example by punching a corresponding blank. A rough contour with a constriction 68 forming legs 21, 22 may be in the step of forming beneficial. Mutually facing inner surfaces of the sections 70, 72 in the region of the constriction may come into contact with one another in the step of forming. In this way, during the forming of the legs 21, 22 result in a favorable force curve. This design may also be advantageous after the forming of the legs 21, 22. When the press-fit contact 100c is pressed into a contact seat 304 (see FIG. 13), the mutually facing inner surfaces of the sections 70, 72 can come into contact with one another. In this way, the stresses generated during pressing in the press-in contact 100c can be defined even more precisely. The embodiment of the press-fit contact 100c illustrated with reference to FIGS. 14a and 14b can furthermore contribute to further reducing stresses in the connection region 6, in which the legs 21, 22 merge into the connection body 1.

Fig. 15 shows in a simplified manner a schematic flow diagram of a method for producing a press-fit. At a step S10, the method may start. This is followed by a step S12, in which a raw shape or rough contour of a press-fit is generated. This can be done in particular by means of a separation process. This is preferably a chipless separation process. For example, the raw contour can be produced by means of stamping, cutting or fine blanking. The raw contour of the press-fit contact preferably comprises a connection body and two leg elements or legs extending therefrom. In particular, the legs may be substantially symmetrical to each other and extend substantially in the longitudinal direction approximately as legs of a V or U. It is preferred if the limbs have contact sections at their end regions facing away from the connection body, which, however, do not touch each other in the rough contour. It may be followed by a step S14, in which a smoothing or rounding of edges of the rough contour of the press-fit takes place. However, step S14 can also be skipped in principle. According to some embodiments, step S14 may be combined with step S12. By way of example, it is conceivable to produce and smooth the rough contour of the press-fit contact by means of a combined stamping / embossing process. By means of embossing burrs and / or punched edges can be defused.

This is followed by a step S16, which includes a deformation of the press-fit. In an advantageous manner, the legs of the press-fit contact, in particular their contact sections, are plastically deformed in such a way that after forming between the contact sections of the legs at least partially a contact results. This can contribute in a special way to improving the dimensional accuracy of the press-fit.

[0085] According to various embodiments, the step of reshaping S16 may comprise various substeps. By way of example, a step S18 may be provided, in which at least one, preferably both legs are deflected laterally. This step may relate in particular to the contact portions of the legs. It may approach a step S20, in which the legs, in particular their contact portions, are moved towards each other. Preferably, the contact portions of the legs are thereby laterally disengaged so that they can be at least partially moved past each other. In this way, the legs can be plastically deformed in a special way. It may be followed by a further step S22, in which the (laterally deflected) legs are laterally returned to their initial position or neutral position. However, since at least one of the legs, preferably both legs, have been plastically deformed in the direction of each other, after returning the legs between the contact sections at least in sections, a contact may result. Preferably, the legs have been deformed such that the contact occurs to produce a bias voltage. In this way, the contact between the contact sections is particularly safe and process technically well reproducible. It may be followed by a step S24, which concludes the process. It is understood that the method can be used to simultaneously manufacture a plurality of press-in contacts, which are formed, for example, in one piece with a suitable support member, such as a busbar. Overall, can be produced with the process press-fit, which are suitable for the transmission of large currents and which are easy and safe to install. The execution of the press-in contacts with two legs whose contact sections are not rigidly connected to each other in principle, but touch each other defined, brings with it various advantages.

A press-fit according to one of the aforementioned aspects is suitable both for permanent press-fit, which are designed as non-detachable connectors, so also for releasable connectors. Detachable connectors can be created and disconnected several times. Accordingly, the press-fit contact, at least according to some embodiments, may also generally be a plug contact.

Claims

claims

1 . Method for producing plug contacts (100, 100a, 100b, 100c) comprising the following steps:

Producing a raw contour, in particular a stamped contour, of a plug-in contact (100, 100a, 100b, 100c), having a connection body (1) and two adjoining legs (21, 22), which are arranged opposite one another, wherein the legs (21 , 22) have press-in regions (5) and end regions (4) facing away from the connector body (1), with contact sections (42, 44) facing each other and definedly spaced from one another; and

Reshaping the legs (21, 22) comprising moving the end portions (4) of the legs (21, 22) toward each other with at least partially plastic deformation of at least one of the legs (21, 22), wherein the contact portions (42, 44) of the legs (21, 22) 21, 22) touch after a discharge at least partially defined.

2. The method of claim 1, wherein the plug contact as a press-in contact (100;

100a; 100b; 100c) is formed.

3. The method of claim 1 or 2, wherein the plastic deformation during forming is introduced such that the contact portions (42, 44) of the legs (21, 22) are biased after forming with a contact force against each other.

4. The method according to any one of the preceding claims, wherein the forming of the legs (21, 22) takes place to form an inner contour (9), which during the assembly of the plug contact (100; 100a; 100b; 100c) a yielding of the legs (21, 22) allowed.

5. The method according to any one of the preceding claims, wherein the forming of the legs (21, 22) further comprises a lateral deflection of at least one of the legs (21, 22), wherein at least the contact portions (42, 44) of the legs (21, 22) are laterally offset from each other in a deflected position.

6. The method of claim 5, wherein both legs (21, 22) are laterally deflected in opposite directions.

7. The method according to claim 5 or 6, wherein the contact portions (42, 44) of the

Leg (21, 22) during the conversion toward each other and at least partially moved past each other.

8. The method according to any one of claims 5 to 7, wherein the lateral deflection substantially under elastic deformation of the legs (21, 22).

9. The method according to any one of claims 5 to 8, wherein the lateral deflection

at least partially under plastic deformation of the legs (21, 22) takes place, wherein the forming further comprises a lateral counter-movement of the two legs (21, 22), whereby the contact portions (42, 44) of the legs (21, 22) in a lateral neutral position be transferred.

10. The method according to any one of the preceding claims, wherein the two legs (21, 22) are punched and formed in such a way that a substantially almond-shaped configuration of the legs (21, 22) results, wherein the two legs (21, 22) preferably be designed substantially mirror-symmetrical and in particular have a convexly outwardly projecting portion.

1 1. Method according to one of the preceding claims, wherein an inside transition between the press-in area and the contact portions (42, 44) of the legs (21, 22) is provided with a rounding.

12. The method of claim 10 or 1 1, wherein the two legs (21, 22) are provided with Einpressbereichen (5) having a substantially convex outer contour and a substantially concave inner contour (9), and wherein between the legs (21, 22) results in a substantially almond-shaped inner recess.

13. The method according to any one of the preceding claims, wherein at least the

Connecting body (1) or the legs (21, 22) are at least partially impressed.

14. The method of claim 1, wherein generating the raw contour further comprises creating a concave constriction at the transition between a press-fit area and a connection area, wherein the concave constriction is curved Sections (70, 72) of the legs (21, 22) is formed.

15. Plug-in contact (100, 100a, 100b, 100c), in particular stamped plug-in contact for generating an electrical connection, with a connecting body (1) and two adjoining curved legs (21, 22), wherein the connecting body (1) and the legs (21, 22) are integrally formed, each leg (21, 22) having a press-in area (5) and an end portion (4) with a contact portion (42, 44), wherein both legs (21, 22) is a substantially almond-shaped Define inner contour (9), and wherein the contact portions (42, 44) of the two legs (21, 22) facing each other and touch at least partially defined.

16. plug contact (100, 100a, 100b, 100c) according to claim 15, wherein the plug contact as Einpresskontakt (100, 100a, 100b, 100c), in particular as a stamped press-fit, is formed.

17. plug contact (100; 100a; 100b; 100c) according to claim 15 or 16, wherein the contact portions (42, 44) of both legs (21, 22) are biased against each other with a contact force.

18. plug contact (100, 100a, 100b, 100c) according to one of claims 15 to 17, wherein the legs (21, 22) have a connection region (6) for connection to the connection body (1), wherein the legs (21, 22 ) at a transition between the press - in region (5) and the connection region (6) have a concave constriction (68) formed by curved sections (70, 72) of the legs (21, 22), the legs (21, 22 Further, at their ends facing the connection body (1), they have an inner curve (7) which merges into the interior space (9), and wherein the concave constriction (68) of the legs (21, 22) forms a constriction between the interior space (9 ) and rounding (7).

19. A component arrangement having at least one contact receptacle (304), in particular a receiving bush, and having at least one plug contact (100; 100a; 100b; 100c) according to one of claims 15 to 18, wherein the plug contact (100; 100a; 100b) under prestress in the contact (304) is recorded.