EP3100322B1 - Method for producing an electrical connector and electrical connector - Google Patents

Method for producing an electrical connector and electrical connector Download PDF

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Publication number
EP3100322B1
EP3100322B1 EP15707286.9A EP15707286A EP3100322B1 EP 3100322 B1 EP3100322 B1 EP 3100322B1 EP 15707286 A EP15707286 A EP 15707286A EP 3100322 B1 EP3100322 B1 EP 3100322B1
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EP
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Prior art keywords
coating
electrically conductive
support element
contact element
plug connector
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EP15707286.9A
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German (de)
French (fr)
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EP3100322A1 (en
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Wolfgang B. THÖRNER
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/02—Contact members
    • H01R13/03—Contact members characterised by the material, e.g. plating, or coating materials
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/16—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for manufacturing contact members, e.g. by punching and by bending

Definitions

  • the invention relates to a method for producing an electrical connector with a contact element.
  • the invention also relates to an electrical plug connector with a contact element.
  • contact elements are predominantly used which have a great deal of conductive mass, so that eddy currents are often the result.
  • Various methods for producing contact elements of electrical connectors are known from the prior art.
  • the contact element is usually produced as a turned part from a material which is suitable for machining on the one hand and is electrically conductive on the other hand.
  • the disadvantage here is that a material suitable for machining usually has a lower conductivity than, for example, the conductive material of the conductor to be connected (e.g. copper). This requires larger cable and contact cross-sections in order to prevent the quality-reducing damping of power pulses.
  • a pronounced skin effect occurs with contact elements designed in this way. Due to the skin effect, the current density inside a conductor is lower than in the outer areas. The skin effect increases the resistance of the electrical line as the frequency of the transmitted signals increases.
  • Eddy currents which occur in the contact elements of connectors due to the transmitted Signals are induced as the eddy currents interfere with the signal currents.
  • materials with high conductivity such as copper and silver. Due to the good conductivity of these materials, the material volume of the contact elements can be significantly reduced. Eddy currents occur correspondingly reduced.
  • Contact elements made of silver are mostly used in connectors with a composite structure made of metal and plastic, with the contact elements being produced as stamped/bent parts that are embedded in the plastic material of a base body of the connector (e.g. by encapsulation in an injection molding process). It is also advantageous that coupling and line capacitances can be reduced due to the greatly reduced mass of the electrically conductive material (see e.g DE 10 2008 007 866 A1 ).
  • the U.S. 5,264,788 A describes a radio frequency probe device having a first probe with a first electrical conductor, a second probe with a second electrical conductor, and a flexible conductive strap for electrically connecting the first electrical conductor to the second electrical conductor.
  • the U.S. 2013/260048 A1 discloses a method for producing an electrically conductive resistance layer, in which an electrically conductive material is applied to a non-conductive substrate, the electrically conductive material initially not having a specific shape and at a later point in time the material layer is removed in certain areas.
  • the U.S. 6,615,483 B2 describes a method for coating an end region of a multi-pole electrode head for stimulating the heart.
  • the U.S. 2006/162287 A1 discloses an anisotropic electrically conductive plate comprising a plate-shaped, electrically conductive elastomer, a non-conductive area surrounded by the elastomer and an electrically conductive area, which in turn is surrounded by the non-conductive area.
  • the U.S. 2,022,314A describes an electrical resistance with a tube made of a refractory material, this being provided with a conductive coating on its outer surface and with a highly conductive material at its ends.
  • this document discloses an electrical connector (1) with a contact element (3), wherein the contact element (3) is at least partially embedded in a base body (2) of the electrical connector (1) made of electrically insulating material or is molded onto it.
  • the electrical connector should be able to be produced easily and inexpensively.
  • at least the frequency-dependent skin effect should be eliminated as far as possible and the formation of eddy currents should be avoided.
  • the method according to the invention makes it possible to produce contact elements which, compared to the prior art, have a greatly reduced mass have electrically conductive material. As a result, they have excellent eddy current behavior, which means that the quality of signal transmission can be improved. Since the electrically conductive coating has only a very small cross section, the frequency-dependent (non-linear) skin effect can be almost completely ruled out.
  • the invention is based on the concept of using a crystalline conductor.
  • the coating is preferably designed as a two-dimensional crystalline layer. It is generally known that crystals are characterized by their regular atomic arrangement in all three spatial directions. In contrast to this, the conductors preferred according to the invention preferably only have a regular or repeated arrangement of the atoms in two spatial directions.
  • the physical properties of two-dimensional crystalline layers differ significantly from the amorphous form of the same material.
  • PVD gas phase deposition processes
  • CVD chemical vapor deposition
  • the carrier element is excluded from the signal line.
  • the carrier element can consist of a plastic material, with the carrier element preferably being produced in an injection molding process from a suitable thermoplastic polymer material of a type known per se.
  • the injection molding process allows directly usable molded parts to be produced in large numbers at low cost.
  • the carrier element consists of a ceramic material.
  • the carrier element can consist of a metallic material that is anodized.
  • Anodizing electrically insulates the metallic carrier body, which is itself initially suitable as a signal conductor, and thus excludes it from the signal line.
  • An electrically insulating ceramic layer is preferably produced on the surface of the carrier element by the anodizing. Ceramic materials are well known in electronics and electrical engineering. Due to their high mechanical strength and very low electrical conductivity, they are particularly suitable as insulators. All known methods are suitable for producing the ceramic layer according to the invention.
  • the carrier element is advantageously made of aluminum or an aluminum alloy. Support elements designed in this way can be produced with tools that are already in use for the production of contact elements. This can save costs. A cost-effective production of the connector according to the invention is thus possible.
  • Aluminum is suitable for anodizing using the anodizing process.
  • the carrier element can consist of titanium or a titanium alloy. Thanks to the use of titanium, the signal conductor has a very high level of strength with an overall low weight. This allows a particularly robust plug connector to be implemented, the contact elements of which are resistant to bending. Titanium carrier elements can also be produced with tools that are already in use for the production of contact elements.
  • the layer of electrically conductive material is carbon.
  • the coating alternatively consists of graphite.
  • Graphite has a particularly high strength along its crystal layer and very good electrical conductivity. Due to the good electrical conductivity, the conductive mass can be kept low. Eddy currents are avoided.
  • graphene is also used for coating the carrier element.
  • Graphene surface crystals are particularly stiff and strong and also have very good electrical conductivity.
  • Graphene layers can be produced extremely thin, possibly as monoatomic layers or layers comprising only a few atomic layers, so that the skin effect is eliminated if the graphene layer forms the sole electrical signal conductor in the sense of the invention.
  • the graphene coating can be obtained by epitaxial growth on the material of the anodized support element using vapor phase deposition.
  • the carbon layer is advantageously produced by plasma coating the carrier element.
  • Plasma coating offers the advantage that good adhesion to the substrate can be achieved. Furthermore, will a high uniformity of the layer thickness and structure and the surface and layer properties can be adjusted within wide limits. It is precisely the uniformity of the layer thickness that plays a decisive role with regard to a skin effect, which according to the invention is to be kept as small as possible or avoided altogether. Rough surfaces have an unfavorable effect on the electrical resistance (contact and line resistance). Furthermore, layers produced in this way are hole-free with a low thickness. Plasma coating is also advantageous from an ecological point of view, because it is a solvent-free and dry process with only a small consumption of chemicals.
  • the subject matter of the invention is also that the carrier element is coated with titanium nitride.
  • the hardness of the titanium nitride layer also ensures that the connector is very strong, making the connector more resistant to bending in particular.
  • Another advantage of the titanium nitride layer is its high scratch resistance. This prevents indentations occurring in the otherwise flat surface as a result of or during use of the connector, which would have an unfavorable effect on the electrical resistance (contact and line resistance) and lead to a deterioration in the eddy current behavior. A durable and high-quality connector is thus created.
  • Common coating processes such as the gas phase deposition process (CVD/PVD) or plasma coating can be used to apply the titanium nitride. Depending on the coating process used, an extremely thin and uniform titanium nitride layer can be produced so that the skin effect is eliminated.
  • an electrically conductive protective coating is applied to the coating.
  • the protective coating protects the underlying layers from mechanical and chemical influences, such as abrasion and/or oxygen.
  • the protective coating contains an electrically conductive material.
  • the protective layer can be made of gold, for example, or another material that is sufficiently electrically conductive.
  • Titanium nitride is particularly well suited as a protective coating.
  • the ceramic material is hard and a good electrical conductor.
  • titanium nitride has good sliding properties, which is an advantage when plugging electrical connectors together.
  • the use of titanium nitride also leads to an attractive external appearance of the connector, since a smooth titanium nitride layer has a high-gloss black or gold color or shows interference color effects.
  • the contact element according to the invention is at least partially encapsulated or encapsulated by a base body of the connector.
  • the base body preferably consists of a plastic.
  • contact elements produced according to the invention can be integrated into already known connector types. A complete conversion of the existing manufacturing processes is therefore not necessary. This saves costs.
  • the present invention further relates to an electrical connector as defined in independent claim 8.
  • the plug connectors according to the invention are preferably designed in such a way that no tools are required to plug the plug connector or the contact element into a corresponding socket or the like or to remove it again.
  • a connector designed in this way has the advantage over the prior art that it has excellent eddy current behavior, as a result of which the quality of the signal transmission can be improved. Since the conductive elements of the connector according to the invention only have a very small cross section, the frequency-dependent (non-linear) skin effect can also be almost completely ruled out according to the invention.
  • the carrier element can consist of a plastic material and is preferably designed as an injection molded part.
  • the injection molding process allows directly usable molded parts to be produced in large numbers at low cost.
  • the carrier element is designed as a stamped/bent part.
  • the carrier element can preferably be made of metallic flat material that is anodized. It is given the shape required for its function by means of flexural deformation. Support elements designed in this way save material and thus costs.
  • the contact element is at least partially embedded in a base body made of electrically insulating material or molded onto it.
  • the base body forms the supporting structure of the connector.
  • the base body is preferably made of a plastic material.
  • the contact element can have recesses into which the insulating body engages.
  • the contact element is embedded in the material of the base body by casting.
  • the contact element is preferably embedded in the base body by injection molding.
  • a connector designed in this way is optimized both in terms of its electrical properties during signal transmission and in terms of manufacturing costs.
  • the connector according to the invention can, for example, be a banana plug, a cinch plug, an XLR plug, an HDMI plug, a pole terminal or a cable lug.
  • FIG 1 shows a schematic side view of an electrical connector according to the invention.
  • the electrical plug connector 1 is designed as an angled banana plug and comprises a base body 2 and a substantially cylindrical contact element 3 protruding from the front side of the base body 2.
  • the contact element 3 is partially embedded in the base body 2 made of plastic.
  • the contact element 3 has at least one carrier element 4, which is coated with an electrically conductive layer, which preferably consists of graphene, with the coating forming the sole electrical signal conductor.
  • the carrier element 4 is made from a metallic flat material, which, by means of bending technology, has the shape required for the function, as shown in 1 is shown receives.
  • the carrier element 4 is a stamped/bent part made of aluminum, which is anodized in an anodizing process and then coated with graphene.
  • the carrier element 4 can also be a body made of plastic. It is essential that the carrier element 4 is not electrically conductive, ie either consists of electrically insulating material or is coated with it. It therefore does not take part in the electrical signal transmission and only acts as a dummy core.
  • FIG 2 shows a schematic sectional representation of the contact element 3.
  • the carrier element 4 consists of a metallic material and is surrounded by a ceramic layer 5 produced by anodizing.
  • the carrier element 4 is electrically insulated by the ceramic layer 5 .
  • the Ceramic layer 5 is covered by an electrically conductive layer 6, which is preferably a carbon layer, which according to the invention forms the sole signal conductor.
  • the coating 6 has the smallest possible layer thickness.
  • the contact element 3 has a protective coating 7 made of titanium nitride as the outer layer.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Manufacturing Of Electrical Connectors (AREA)
  • Connector Housings Or Holding Contact Members (AREA)

Description

Die Erfindung betrifft ein Verfahren zur Herstellung eines elektrischen Steckverbinders mit einem Kontaktelement. Außerdem betrifft die Erfindung einen elektrischen Steckverbinder mit einem Kontaktelement.The invention relates to a method for producing an electrical connector with a contact element. The invention also relates to an electrical plug connector with a contact element.

Um den Anforderungen hinsichtlich elektrischer und mechanischer Funktion von Kontaktelementen in elektrischen Steckverbindern gerecht zu werden, werden überwiegend Kontaktelemente verwendet, die sehr viel leitende Masse aufweisen, so dass Wirbelströme häufig die Folge sind. Aus dem Stand der Technik sind verschiedene Verfahren zur Herstellung von Kontaktelementen von elektrischen Steckverbindern bekannt. Bei den bekannten Steckverbindern wird das Kontaktelement gewöhnlich als Drehteil aus einem Material hergestellt, das einerseits für die spanende Bearbeitung geeignet und anderseits elektrisch leitfähig ist. Nachteilig hierbei ist, dass ein für die spanende Bearbeitung geeignetes Material meist eine niedrigere Leitfähigkeit aufweist als beispielsweise das leitende Material des anzuschließenden Leiters (z.B. Kupfer). Das erfordert größere Leitungs- und Kontaktquerschnitte, um die qualitätsmindernde Dämpfung von Leistungsimpulsen zu unterbinden. Ferner tritt bei derart ausgebildeten Kontaktelementen ein ausgeprägter Skin-Effekt auf. Durch den Skin-Effekt ist die Stromdichte im Inneren eines Leiters niedriger als in äußeren Bereichen. Der Skin-Effekt erhöht mit zunehmender Frequenz der übertragenen Signale den Widerstandsbelag der elektrischen Leitung.In order to meet the requirements with regard to the electrical and mechanical function of contact elements in electrical connectors, contact elements are predominantly used which have a great deal of conductive mass, so that eddy currents are often the result. Various methods for producing contact elements of electrical connectors are known from the prior art. In the case of the known connectors, the contact element is usually produced as a turned part from a material which is suitable for machining on the one hand and is electrically conductive on the other hand. The disadvantage here is that a material suitable for machining usually has a lower conductivity than, for example, the conductive material of the conductor to be connected (e.g. copper). This requires larger cable and contact cross-sections in order to prevent the quality-reducing damping of power pulses. Furthermore, a pronounced skin effect occurs with contact elements designed in this way. Due to the skin effect, the current density inside a conductor is lower than in the outer areas. The skin effect increases the resistance of the electrical line as the frequency of the transmitted signals increases.

Ebenfalls nachteilig für die Qualität der Signalübertragung können Wirbelströme sein, die in den Kontaktelementen von Steckverbindern durch die übertragenen Signale induziert werden, da die Wirbelströme mit den Signalströmen interferieren. Um Wirbelströme möglichst gering zu halten, ist es bekannt Materialien mit hoher Leitfähigkeit, wie Kupfer und Silber, zu verwenden. Aufgrund der guten Leitfähigkeit dieser Materialien kann das Materialvolumen der Kontaktelemente erheblich reduziert werden. Wirbelströme treten entsprechend vermindert auf. Kontaktelemente aus Silber werden meist in Steckverbindern mit einem Verbundaufbau aus Metall und Kunststoff eingesetzt, wobei die Kontaktelemente als Stanz-/Biegeteile hergestellt werden, die in das Kunststoffmaterial eines Grundkörpers des Steckverbinders (z.B. durch Umgießen in einem Spritzgießverfahren) eingebettet werden. Vorteilhaft ist dabei auch, dass Kopplungs- und Leitungskapazitäten aufgrund der stark reduzierten Masse des elektrisch leitenden Materials vermindert werden können (siehe z.B. DE 10 2008 007 866 A1 ).Eddy currents, which occur in the contact elements of connectors due to the transmitted Signals are induced as the eddy currents interfere with the signal currents. In order to keep eddy currents as low as possible, it is known to use materials with high conductivity, such as copper and silver. Due to the good conductivity of these materials, the material volume of the contact elements can be significantly reduced. Eddy currents occur correspondingly reduced. Contact elements made of silver are mostly used in connectors with a composite structure made of metal and plastic, with the contact elements being produced as stamped/bent parts that are embedded in the plastic material of a base body of the connector (e.g. by encapsulation in an injection molding process). It is also advantageous that coupling and line capacitances can be reduced due to the greatly reduced mass of the electrically conductive material (see e.g DE 10 2008 007 866 A1 ).

Die US 5 264 788 A beschreibt eine Hochfrequenzsondenvorrichtung mit einer ersten Sonde mit einem ersten elektrischen Leiter, einer zweiten Sonde mit einem zweiten elektrischen Leiter und einem flexibel leitenden Band zum elektrischen Verbinden des ersten elektrischen Leiters mit dem zweiten elektrischen Leiter.the U.S. 5,264,788 A describes a radio frequency probe device having a first probe with a first electrical conductor, a second probe with a second electrical conductor, and a flexible conductive strap for electrically connecting the first electrical conductor to the second electrical conductor.

Die US 2013 / 260048 A1 offenbart ein Verfahren zum Herstellen einer elektrisch leitenden Widerstandsschicht, bei dem ein elektrisch leitendes Material auf einen nicht leitenden Untergrund aufgebracht wird, wobei das elektrisch leitende Material zunächst noch keine bestimmte Form aufweist und zu einem späteren Zeitpunkt die Materialschicht bereichsweise entfernt wird.the U.S. 2013/260048 A1 discloses a method for producing an electrically conductive resistance layer, in which an electrically conductive material is applied to a non-conductive substrate, the electrically conductive material initially not having a specific shape and at a later point in time the material layer is removed in certain areas.

Die US 6 615 483 B2 beschreibt ein Verfahren zur Beschichtung eines Endbereichs eines mehrpoligen Elektrodenkopfes zur Stimulation des Herzens.the U.S. 6,615,483 B2 describes a method for coating an end region of a multi-pole electrode head for stimulating the heart.

Die US 2006 / 162287 A1 offenbart eine anisotrope elektrisch leitfähige Platte aufweisend einen plattenförmig ausgebildeten, elektrisch leitfähigen Elastomer, einen nichtleitfähigen Bereich, der von dem Elastomer umgeben ist und einen elektrisch leitenden Bereich, der von dem nichtleitenden Bereich wiederum umgeben ist.the U.S. 2006/162287 A1 discloses an anisotropic electrically conductive plate comprising a plate-shaped, electrically conductive elastomer, a non-conductive area surrounded by the elastomer and an electrically conductive area, which in turn is surrounded by the non-conductive area.

Die US 2 022 314 A beschreibt einen elektrischen Widerstand mit einem Rohr aus einem feuerfesten Material, wobei dieses auf seiner Mantelfläche mit einer leitfähigen Beschichtung und an seinen Enden mit einem hochgradig leitfähigen Material versehen ist.the U.S. 2,022,314A describes an electrical resistance with a tube made of a refractory material, this being provided with a conductive coating on its outer surface and with a highly conductive material at its ends.

DE 10 2008 007866 A1 offenbart (die Verweise in Klammern beziehen sich auf dieses Dokument) ein Verfahren zur Herstellung eines elektrischen Steckverbinders (1), mit den folgenden Schritten:

  • Herstellung eines Kontaktelementes (3); und
  • Umgießen des Kontaktelementes (3) zur zumindest teilweisen Einbettung des Kontaktelementes (3) in einem Grundkörper (2) des Steckverbinders (1) aus elektrisch isolierendem Material.
DE 10 2008 007866 A1 discloses (the references in brackets refer to this document) a method of manufacturing an electrical connector (1), comprising the following steps:
  • Production of a contact element (3); and
  • Casting of the contact element (3) to at least partially embed the contact element (3) in a base body (2) of the connector (1) made of electrically insulating material.

Des Weiteren offenbart dieses Dokument ein elektrischer Steckverbinder (1) mit einem Kontaktelement (3),
wobei das Kontaktelement (3) zumindest teilweise in einen Grundkörper (2) des elektrischer Steckverbinders (1) aus elektrisch isolierendem Material eingebettet oder an diesen angeformt ist.Furthermore, this document discloses an electrical connector (1) with a contact element (3),
wherein the contact element (3) is at least partially embedded in a base body (2) of the electrical connector (1) made of electrically insulating material or is molded onto it.

Es ist Aufgabe der Erfindung, einen elektrischen Steckverbinder mit einem verbesserten Kontaktelement bereit zu stellen. Der elektrische Steckverbinder soll kostengünstig und einfach hergestellt werden können. Außerdem soll zumindest der frequenzabhängige Skin-Effekt so weit wie möglich eliminiert werden und die Entstehung von Wirbelstrom vermieden werden.It is the object of the invention to provide an electrical connector with an improved contact element. The electrical connector should be able to be produced easily and inexpensively. In addition, at least the frequency-dependent skin effect should be eliminated as far as possible and the formation of eddy currents should be avoided.

Gelöst wird diese Aufgabe durch ein Verfahren mit den Merkmalen des Anspruchs 1 sowie durch einen elektrischen Steckverbinder mit den Merkmalen des Anspruchs 8. Vorteilhafte Ausgestaltungen sind Gegenstand der abhängigen Ansprüche. Es ist darauf hinzuweisen, dass die in den Ansprüchen einzeln aufgeführten Merkmale beliebig miteinander kombiniert werden können und somit weitere Ausgestaltungen der Erfindung aufzeigen.This object is achieved by a method having the features of claim 1 and by an electrical connector having the features of claim 8. Advantageous configurations are the subject matter of the dependent claims. It should be pointed out that the features listed individually in the claims can be combined with one another as desired and thus show further refinements of the invention.

Das erfindungsgemäße Verfahren zur Herstellung eines elektrischen Steckverbinders ist nach unabhängigem Anspruch 1 definiert.The method according to the invention for producing an electrical connector is defined according to independent claim 1.

Durch das erfindungsgemäße Verfahren können Kontaktelemente hergestellt werden, die gegenüber dem Stand der Technik eine stark reduzierte Masse des elektrisch leitenden Materials aufweisen. Hierdurch weisen sie ein hervorragendes Wirbelstromverhalten auf, wodurch die Qualität der Signalübertragung verbessert werden kann. Da die elektrisch leitende Beschichtung nur einen sehr kleinen Querschnitt aufweist, kann zudem der frequenzabhängige (nicht-lineare) Skin-Effekt fast vollständig ausgeschlossen werden.The method according to the invention makes it possible to produce contact elements which, compared to the prior art, have a greatly reduced mass have electrically conductive material. As a result, they have excellent eddy current behavior, which means that the quality of signal transmission can be improved. Since the electrically conductive coating has only a very small cross section, the frequency-dependent (non-linear) skin effect can be almost completely ruled out.

Der Erfindung liegt das Konzept zu Grunde, einen kristallinen Leiter zu verwenden. Bevorzugt ist die Beschichtung als zweidimensionale kristalline Schicht ausgebildet. Allgemein ist bekannt, dass sich Kristalle durch ihre regelmäßige Atomanordnung in allen drei Raumrichtungen auszeichnen. Die erfindungsgemäß bevorzugten Leiter weisen im Gegensatz dazu bevorzugt nur eine regelmäßige bzw. sich wiederholende Anordnung der Atome in zwei Raumrichtungen auf. Die physikalischen Eigenschaften von zweidimensionalen kristallinen Schichten weichen signifikant von der amorphen Form des gleichen Materials ab.The invention is based on the concept of using a crystalline conductor. The coating is preferably designed as a two-dimensional crystalline layer. It is generally known that crystals are characterized by their regular atomic arrangement in all three spatial directions. In contrast to this, the conductors preferred according to the invention preferably only have a regular or repeated arrangement of the atoms in two spatial directions. The physical properties of two-dimensional crystalline layers differ significantly from the amorphous form of the same material.

Für das Aufbringen der elektrisch leitenden Beschichtung können gängige Beschichtungsverfahren, wie z.B. Gasphasenabscheidungsverfahren (PVD, CVD) verwendet werden.Common coating processes, such as gas phase deposition processes (PVD, CVD), can be used to apply the electrically conductive coating.

Erfindungsgemäß ist das Trägerelement von der Signalleitung ausgeschlossen. Das Trägerelement kann aus einem Kunststoffmaterial bestehen, wobei das Trägerelement bevorzugt im Spritzgussverfahren aus einem geeigneten thermoplastischen Polymermaterial an sich bekannter Art hergestellt wird. Durch das Spritzgussverfahren lassen sich direkt verwendbare Formteile in großer Stückzahl kostengünstig herstellen. Denkbar ist aber auch, dass das Trägerelement aus einem keramischen Werkstoff besteht.According to the invention, the carrier element is excluded from the signal line. The carrier element can consist of a plastic material, with the carrier element preferably being produced in an injection molding process from a suitable thermoplastic polymer material of a type known per se. The injection molding process allows directly usable molded parts to be produced in large numbers at low cost. However, it is also conceivable that the carrier element consists of a ceramic material.

Vorteilhafterweise kann das Trägerelement aus einem metallischen Werkstoff bestehen, der anodisiert wird. Durch das Anodisieren wird der metallische Trägerkörper, der sich zunächst selbst als Signalleiter eignet, elektrisch isoliert und damit von der Signalleitung ausgeschlossen. Bevorzugt wird durch das Anodisieren eine elektrisch isolierende Keramikschicht auf der Oberfläche des Trägerelementes erzeugt. Keramische Materialien sind in der Elektronik und Elektrotechnik allgemein bekannt. Durch ihre hohe mechanische Belastbarkeit und sehr geringe elektrische Leitfähigkeit sind sie als Isolatoren besonders geeignet. Für die Erzeugung der erfindungsgemäßen Keramikschicht eignen sich alle bekannten Verfahren.Advantageously, the carrier element can consist of a metallic material that is anodized. Anodizing electrically insulates the metallic carrier body, which is itself initially suitable as a signal conductor, and thus excludes it from the signal line. An electrically insulating ceramic layer is preferably produced on the surface of the carrier element by the anodizing. Ceramic materials are well known in electronics and electrical engineering. Due to their high mechanical strength and very low electrical conductivity, they are particularly suitable as insulators. All known methods are suitable for producing the ceramic layer according to the invention.

Vorteilhafterweise besteht das Trägerelement aus Aluminium oder einer Aluminiumlegierung. Derart ausgebildete Trägerelemente können mit Werkzeugen hergestellt werden, die bereits für die Fertigung von Kontaktelementen im Einsatz sind. Hierdurch können Kosten eingespart werden. Eine kostengünstige Herstellung der erfindungsgemäßen Steckverbinder ist somit möglich. Aluminium eignet sich für die Anodisierung durch das Eloxal-Verfahren.The carrier element is advantageously made of aluminum or an aluminum alloy. Support elements designed in this way can be produced with tools that are already in use for the production of contact elements. This can save costs. A cost-effective production of the connector according to the invention is thus possible. Aluminum is suitable for anodizing using the anodizing process.

Ferner kann das Trägerelement aus Titan oder einer Titanlegierung bestehen. Durch die Verwendung von Titan weist der Signalleiter eine sehr hohe Festigkeit bei insgesamt geringem Gewicht auf. Damit lässt sich ein besonders robuster Steckverbinder realisieren, dessen Kontaktelemente widerstandsfähig gegen Verbiegen sind. Auch Trägerelemente aus Titan lassen sich mit Werkzeugen herstellen, die bereits für die Fertigung von Kontaktelementen im Einsatz sind.Furthermore, the carrier element can consist of titanium or a titanium alloy. Thanks to the use of titanium, the signal conductor has a very high level of strength with an overall low weight. This allows a particularly robust plug connector to be implemented, the contact elements of which are resistant to bending. Titanium carrier elements can also be produced with tools that are already in use for the production of contact elements.

Erfindungsgemäß handelt es sich bei der Schicht aus elektrisch leitendem Material um Kohlenstoff. Erfindungsgemäß besteht die Beschichtung alternativ aus Graphit. Graphit weist entlang seiner Kristallschicht eine besonders hohe Festigkeit und eine sehr gute elektrische Leitfähigkeit auf. Aufgrund der guten elektrischen Leitfähigkeit kann die leitende Masse gering gehalten werden. Wirbelströme werden vermieden.According to the invention, the layer of electrically conductive material is carbon. According to the invention, the coating alternatively consists of graphite. Graphite has a particularly high strength along its crystal layer and very good electrical conductivity. Due to the good electrical conductivity, the conductive mass can be kept low. Eddy currents are avoided.

Erfindungsgemäß wird zum Beschichten des Trägerelements zudem Graphen verwendet. Graphenflächenkristalle sind besonders steif und fest und weisen zudem eine sehr gute elektrische Leitfähigkeit auf. Graphenschichten können, ggf. als monoatomare oder nur wenige Atomlagen umfassende Schichten, extrem dünn hergestellt werden, so dass der Skin-Effekt eliminiert wird, wenn die Graphenschicht im Sinne der Erfindung den alleinigen elektrischen Signalleiter bildet. Die Graphenbeschichtung kann durch epitaktisches Wachstum auf dem Material des anodisierten Trägerelementes mittels Gasphasenabscheidung erfolgen.According to the invention, graphene is also used for coating the carrier element. Graphene surface crystals are particularly stiff and strong and also have very good electrical conductivity. Graphene layers can be produced extremely thin, possibly as monoatomic layers or layers comprising only a few atomic layers, so that the skin effect is eliminated if the graphene layer forms the sole electrical signal conductor in the sense of the invention. The graphene coating can be obtained by epitaxial growth on the material of the anodized support element using vapor phase deposition.

Vorteilhafterweise wird die Kohlenstoffschicht durch Plasmabeschichtung des Trägerelementes erzeugt. Die Plasmabeschichtung bietet den Vorteil, dass hierdurch eine gute Haftung zum Substrat erreicht werden kann. Ferner wird eine hohe Gleichmäßigkeit der Schichtdicke und Struktur bewirkt und die Oberflächen- und Schichteigenschaften können in weiten Grenzen gezielt eingestellt werden. Gerade die Gleichmäßigkeit der Schichtdickte spielt im Hinblick auf einen Skin-Effekt, der erfindungsgemäß möglichst gering gehalten bzw. ganz vermieden werden soll, eine entscheidende Rolle. Raue Oberflächen wirken sich ungünstig auf den elektrischen Widerstand (Kontakt- und Leitungswiderstand) aus. Ferner sind derart hergestellten Schichten bei geringer Dicke lochfrei. Auch ist die Plasmabeschichtung unter ökologischen Aspekten vorteilhaft, denn es handelt sich um einen lösungsmittelfreien und trockenen Prozess, bei einem nur geringen Verbrauch von Chemikalien.The carbon layer is advantageously produced by plasma coating the carrier element. Plasma coating offers the advantage that good adhesion to the substrate can be achieved. Furthermore, will a high uniformity of the layer thickness and structure and the surface and layer properties can be adjusted within wide limits. It is precisely the uniformity of the layer thickness that plays a decisive role with regard to a skin effect, which according to the invention is to be kept as small as possible or avoided altogether. Rough surfaces have an unfavorable effect on the electrical resistance (contact and line resistance). Furthermore, layers produced in this way are hole-free with a low thickness. Plasma coating is also advantageous from an ecological point of view, because it is a solvent-free and dry process with only a small consumption of chemicals.

Gegenstand der Erfindung ist ferner, dass das Trägerelement mit Titannitrid beschichtet wird. Zusätzlich zur Funktion als Signaleiter sorgt die Titannitridschicht durch ihre Härte auch für eine hohe Festigkeit des Steckverbinders, wodurch der Steckverbinder insbesondere widerstandsfähiger gegen Verbiegen wird. Vorteilhaft an der Titannitridschicht ist zudem auch ihre hohe Kratzbeständigkeit. Hierdurch wird verhindert, dass durch die Benutzung bzw. während der Benutzung des Steckverbinders Vertiefungen in der sonst planen Oberfläche entstehen, die sich ungünstig auf den elektrischen Widerstand (Kontakt- und Leitungswiderstand) auswirken und zu einer Verschlechterung des Wirbelstromverhaltens führen würden. Ein langlebiger und qualitativ hochwertiger Steckverbinder wird somit geschaffen. Für das Aufbringen des Titannitrids können gängige Beschichtungsverfahren, wie z.B. das Gasphasenabscheidungsverfahren (CVD/PVD) oder auch die Plasmabeschichtung verwendet werden. Je nach verwendetem Beschichtungsverfahren kann so eine extrem dünne und gleichmäßige Titannitridschicht hergestellt werden, so dass der Skin-Effekt eliminiert wird.The subject matter of the invention is also that the carrier element is coated with titanium nitride. In addition to its function as a signal conductor, the hardness of the titanium nitride layer also ensures that the connector is very strong, making the connector more resistant to bending in particular. Another advantage of the titanium nitride layer is its high scratch resistance. This prevents indentations occurring in the otherwise flat surface as a result of or during use of the connector, which would have an unfavorable effect on the electrical resistance (contact and line resistance) and lead to a deterioration in the eddy current behavior. A durable and high-quality connector is thus created. Common coating processes such as the gas phase deposition process (CVD/PVD) or plasma coating can be used to apply the titanium nitride. Depending on the coating process used, an extremely thin and uniform titanium nitride layer can be produced so that the skin effect is eliminated.

Bei einer bevorzugten Ausgestaltung der Erfindung ist vorgesehen, dass auf die Beschichtung eine elektrisch leitende Schutzbeschichtung aufgebracht wird. Die Schutzbeschichtung schützt die darunterliegenden Schichten vor mechanischen und chemischen Einflüssen, wie beispielsweise Abrieb und/oder Sauerstoff.In a preferred embodiment of the invention, it is provided that an electrically conductive protective coating is applied to the coating. The protective coating protects the underlying layers from mechanical and chemical influences, such as abrasion and/or oxygen.

Die Schutzbeschichtung enthält ein elektrisch leitendes Material. Die Schutzschicht kann z.B. aus Gold oder einem anderen elektrisch hinreichend gut leitfähigen Material bestehen.The protective coating contains an electrically conductive material. The protective layer can be made of gold, for example, or another material that is sufficiently electrically conductive.

Titannitrid ist besonders gut als Schutzbeschichtung geeignet. Das keramische Material ist ein Hartstoff und ein guter elektrischer Leiter. Weiterhin weist Titannitrid gute Gleiteigenschaften auf, was beim Zusammenstecken von elektrischen Steckverbindern von Vorteil ist. Die Verwendung von Titannitrid führt außerdem zu einem ansprechenden äußeren Erscheinungsbild des Steckverbinders, da eine glatte Titannitridschicht hochglänzend schwarz oder goldfarben ist oder Interferenzfarbeffekte zeigt.Titanium nitride is particularly well suited as a protective coating. The ceramic material is hard and a good electrical conductor. Furthermore, titanium nitride has good sliding properties, which is an advantage when plugging electrical connectors together. The use of titanium nitride also leads to an attractive external appearance of the connector, since a smooth titanium nitride layer has a high-gloss black or gold color or shows interference color effects.

Das erfindungsgemäße Kontaktelement ist wenigstens teilweise von einem Grundkörper des Steckverbinders umgossen bzw. umspritzt. Bevorzugt besteht der Grundkörper aus einem Kunststoff.The contact element according to the invention is at least partially encapsulated or encapsulated by a base body of the connector. The base body preferably consists of a plastic.

Ferner können die erfindungsgemäß hergestellten Kontaktelemente in bereits bekannte Steckverbindertypen integriert werden. Eine komplette Umstellung der vorhandenen Herstellungsprozesse ist somit nicht notwendig. Dadurch werden Kosten eingespart.Furthermore, the contact elements produced according to the invention can be integrated into already known connector types. A complete conversion of the existing manufacturing processes is therefore not necessary. This saves costs.

Die vorliegende Erfindung betrifft ferner einen elektrischen Steckverbinder nach unabhängigem Anspruch 8 definiert.The present invention further relates to an electrical connector as defined in independent claim 8.

Die erfindungsgemäßen Steckverbinder sind vorzugsweise derart ausgebildet, dass keine Werkzeuge notwendig sind, um die Steckverbinder bzw. das Kontaktelement in eine entsprechende Buchse oder dergleichen zu stecken bzw. aus dieser wieder zu entfernen.The plug connectors according to the invention are preferably designed in such a way that no tools are required to plug the plug connector or the contact element into a corresponding socket or the like or to remove it again.

Ein derart ausgebildeter Steckverbinder weist aufgrund der stark reduzierten Masse des elektrisch leitenden Materials gegenüber dem Stand der Technik den Vorteil auf, dass er ein hervorragendes Wirbelstromverhalten aufweist, wodurch die Qualität der Signalübertragung verbessert werden kann. Da die leitenden Elemente des erfindungsgemäßen Steckverbinders nur einen sehr kleinen Querschnitt aufweisen, kann erfindungsgemäß auch der frequenzabhängige (nicht-lineare) Skin-Effekt fast vollständig ausgeschlossen werden.Due to the greatly reduced mass of the electrically conductive material, a connector designed in this way has the advantage over the prior art that it has excellent eddy current behavior, as a result of which the quality of the signal transmission can be improved. Since the conductive elements of the connector according to the invention only have a very small cross section, the frequency-dependent (non-linear) skin effect can also be almost completely ruled out according to the invention.

Das Trägerelement kann aus einem Kunststoffmaterial bestehen und ist bevorzugt als Spritzgussteil ausgebildet. Durch das Spritzgussverfahren lassen sich direkt verwendbare Formteile in großer Stückzahl kostengünstig herstellen.The carrier element can consist of a plastic material and is preferably designed as an injection molded part. The injection molding process allows directly usable molded parts to be produced in large numbers at low cost.

Denkbar ist ferner, dass das Trägerelement als Stanz-/Biegeteil ausgebildet ist. Das Trägerelement kann bevorzugt aus metallischem Flachmaterial, das anodisiert ist, hergestellt werden. Durch biegetechnische Verformung erhält es die für die Funktion erforderliche Form. Durch derart ausgebildete Trägerelemente werden Material und somit Kosten eingespart.It is also conceivable that the carrier element is designed as a stamped/bent part. The carrier element can preferably be made of metallic flat material that is anodized. It is given the shape required for its function by means of flexural deformation. Support elements designed in this way save material and thus costs.

Das Kontaktelement ist zumindest teilweise in einen Grundkörper aus elektrisch isolierendem Material eingebettet oder an diesen angeformt. Der Grundkörper bildet die tragende Struktur des Steckverbinders. Der Grundkörper besteht bevorzugt aus einem Kunststoffmaterial. Um eine formschlüssige und feste Verbindung zwischen Kontaktelement und Grundkörper zu gewährleisten, kann das Kontaktelement Ausnehmungen aufweisen, in die der Isolierkörper eingreift.The contact element is at least partially embedded in a base body made of electrically insulating material or molded onto it. The base body forms the supporting structure of the connector. The base body is preferably made of a plastic material. In order to ensure a positive and firm connection between the contact element and the base body, the contact element can have recesses into which the insulating body engages.

Das Kontaktelement ist durch Umgießen in das Material des Grundkörpers eingebettet. Bevorzugt ist das Kontaktelement durch Spritzgießen in den Grundkörper eingebettet. Ein derart ausgebildeter Steckverbinder ist sowohl hinsichtlich seiner elektrischen Eigenschaften bei der Signalübertragung als auch hinsichtlich der Herstellungskosten optimiert.The contact element is embedded in the material of the base body by casting. The contact element is preferably embedded in the base body by injection molding. A connector designed in this way is optimized both in terms of its electrical properties during signal transmission and in terms of manufacturing costs.

Der erfindungsgemäße Steckverbinder kann beispielsweise ein Bananenstecker, ein Cinch-Stecker, ein XLR-Stecker, ein HDMI-Stecker, eine Polklemme oder ein Kabelschuh sein.The connector according to the invention can, for example, be a banana plug, a cinch plug, an XLR plug, an HDMI plug, a pole terminal or a cable lug.

Ausführungsbeispiele der Erfindung sowie das technische Umfeld werden nachfolgend anhand der Zeichnungen näher erläutert. Die Erfindung ist nicht auf die gezeigten Ausführungsbeispiele beschränkt.Exemplary embodiments of the invention and the technical environment are explained in more detail below with reference to the drawings. The invention is not limited to the exemplary embodiments shown.

Es zeigen:

Fig. 1
schematische Seitenansicht eines erfindungsgemäßen elektrischen Steckverbinders;
Fig. 2
schematische Schnittdarstellung eines erfindungsgemäßen Kontaktelementes.
Show it:
1
schematic side view of an electrical connector according to the invention;
2
schematic sectional view of a contact element according to the invention.

Figur 1 zeigt eine schematische Seitenansicht eines erfindungsgemäßen elektrischen Steckverbinders. Der elektrische Steckverbinder 1 ist als Winkelbananenstecker ausgebildet und umfasst einen Grundkörper 2 sowie ein an der Vorderseite des Grundkörpers 2 heraustretendes, im Wesentlichen zylindrisches Kontaktelement 3. Das Kontaktelement 3 ist teilweise in dem aus Kunststoff bestehenden Grundkörper 2 eingebettet. Das Kontaktelement 3 weist zumindest ein Trägerelement 4 auf, das mit einer elektrisch leitenden Schicht, die bevorzugt aus Graphen besteht, beschichtet ist, wobei die Beschichtung den alleinigen elektrischen Signalleiter bildet. Das Trägerelement 4 wird dabei aus einem metallischen Flachmaterial hergestellt, das durch biegetechnische Verformung die für die Funktion erforderliche Form, wie sie in Fig. 1 dargestellt ist, erhält. Das Trägerelement 4 ist ein Stanz-/Biegeteil aus Aluminium, das in einem Eloxal-Verfahren anodisiert und dann mit Graphen beschichtet wird. Bei dem Trägerelement 4 kann es sich aber auch um einen Körper aus Kunststoff handeln. Wesentlich ist, dass das Trägerelement 4 nicht elektrisch leitend ist, d.h. entweder aus elektrisch isolierenden Material besteht oder damit beschichtet ist. Es nimmt damit nicht an der elektrischen Signalübertragung teil und fungiert gleichsam nur als Blindkern. figure 1 shows a schematic side view of an electrical connector according to the invention. The electrical plug connector 1 is designed as an angled banana plug and comprises a base body 2 and a substantially cylindrical contact element 3 protruding from the front side of the base body 2. The contact element 3 is partially embedded in the base body 2 made of plastic. The contact element 3 has at least one carrier element 4, which is coated with an electrically conductive layer, which preferably consists of graphene, with the coating forming the sole electrical signal conductor. The carrier element 4 is made from a metallic flat material, which, by means of bending technology, has the shape required for the function, as shown in 1 is shown receives. The carrier element 4 is a stamped/bent part made of aluminum, which is anodized in an anodizing process and then coated with graphene. However, the carrier element 4 can also be a body made of plastic. It is essential that the carrier element 4 is not electrically conductive, ie either consists of electrically insulating material or is coated with it. It therefore does not take part in the electrical signal transmission and only acts as a dummy core.

Figur 2 zeigt eine schematische Schnittdarstellung des Kontaktelements 3. Das Trägerelement 4 besteht aus einem metallischen Werkstoff und ist von einer durch Eloxieren erzeugten Keramikschicht 5 umgeben. Durch die Keramikschicht 5 wird das Trägerelement 4 elektrisch isoliert. Die Keramikschicht 5 ist von einer elektrisch leitenden Schicht 6, bei der es sich bevorzugt um eine Kohlenstoffschicht handelt, überzogen, die erfindungsgemäß den alleinigen Signalleiter bildet. Die Beschichtung 6 weist dabei eine möglichst geringe Schichtdicke auf. Um das Kontaktelement 3 vor äußeren Einflüssen, wie Luft und Abrieb, zu schützen, weist das Kontaktelement 3 als äußere Schicht eine Schutzbeschichtung 7 aus Titannitrid auf. figure 2 shows a schematic sectional representation of the contact element 3. The carrier element 4 consists of a metallic material and is surrounded by a ceramic layer 5 produced by anodizing. The carrier element 4 is electrically insulated by the ceramic layer 5 . the Ceramic layer 5 is covered by an electrically conductive layer 6, which is preferably a carbon layer, which according to the invention forms the sole signal conductor. The coating 6 has the smallest possible layer thickness. In order to protect the contact element 3 from external influences, such as air and abrasion, the contact element 3 has a protective coating 7 made of titanium nitride as the outer layer.

Claims (12)

  1. Method for manufacturing an electrical plug connector (1), comprising the following steps:
    - manufacture of a contact element (3) by providing an electrically non-conductive support element (4) and coating the support element (4) with an electrically conductive material, wherein the produced coating (6) forms the sole electrical signal conductor, wherein the electrically conductive coating (6) is a carbon layer, a graphene layer or a graphite layer or the electrically conductive coating (6) consists of titanium nitride,
    - encapsulation of the contact element (3) for at least partial embedding of the contact element (3) in a base body (2) of the plug connector (1) made of electrically insulating material.
  2. Method according to claim 1, characterised in that the support element (4) consists of plastic.
  3. Method according to claim 1, characterised in that the support element (4) consists of a metal material and is anodised, whereby the support element (4) is electrically insulated.
  4. Method according to claim 3, characterised in that the support element (4) consists of aluminium or an aluminium alloy or titanium or a titanium alloy.
  5. Method according to any one of the preceding claims, characterised in that the coating (6) is produced by plasma coating of the support element (4).
  6. Method according to any one of the preceding claims, characterised in that an electrically conductive protective coating (7) is applied to the coating (6) forming the sole electrical signal conductor.
  7. Method according to claim 6, characterised in that the protective coating (7) contains titanium nitride.
  8. Electrical plug connector (1) with a contact element (3), wherein the contact element (3) comprises an electrically non-conductive support element (4), which is coated with an electrically conductive material, wherein the coating (6) forms the sole electrical signal conductor, wherein the electrically conductive coating (6) is a carbon layer, a graphene layer or a graphite layer or the electrically conductive coating (6) consists of titanium nitride, wherein the contact element (3) is embedded at least partially into a base body (2) of the electrical plug connector (1) made of electrically insulating material or is moulded onto this.
  9. Electrical plug connector (1) according to claim 8, characterised in that the support element (4) is metal and has an electrically insulating ceramic layer (5) on its surface.
  10. Electrical plug connector (1) according to claim 8, characterised in that the support element (4) consists of plastic.
  11. Electrical plug connector (1) according to any one of claims 8 to 10, characterised in that an electrically conductive protective coating is arranged on the coating (6) forming the sole electrical signal conductor.
  12. Electrical plug connector (1) according to any one of claims 8 to 11, characterised in that the contact element (3) is manufactured according to the method according to any one of claims 1 to 7.
EP15707286.9A 2014-01-28 2015-01-27 Method for producing an electrical connector and electrical connector Active EP3100322B1 (en)

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