EP3772784A1 - Two-row connector for a strip or film cable, method for producing the same, and power transmission device - Google Patents
Two-row connector for a strip or film cable, method for producing the same, and power transmission device Download PDFInfo
- Publication number
- EP3772784A1 EP3772784A1 EP19315086.9A EP19315086A EP3772784A1 EP 3772784 A1 EP3772784 A1 EP 3772784A1 EP 19315086 A EP19315086 A EP 19315086A EP 3772784 A1 EP3772784 A1 EP 3772784A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- connecting element
- conductors
- flat part
- contact pins
- plane
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Images
Classifications
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
- H01R43/16—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for manufacturing contact members, e.g. by punching and by bending
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
- H01R13/02—Contact members
- H01R13/04—Pins or blades for co-operation with sockets
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R24/00—Two-part coupling devices, or either of their cooperating parts, characterised by their overall structure
- H01R24/28—Coupling parts carrying pins, blades or analogous contacts and secured only to wire or cable
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R12/00—Structural associations of a plurality of mutually-insulated electrical connecting elements, specially adapted for printed circuits, e.g. printed circuit boards [PCB], flat or ribbon cables, or like generally planar structures, e.g. terminal strips, terminal blocks; Coupling devices specially adapted for printed circuits, flat or ribbon cables, or like generally planar structures; Terminals specially adapted for contact with, or insertion into, printed circuits, flat or ribbon cables, or like generally planar structures
- H01R12/50—Fixed connections
- H01R12/59—Fixed connections for flexible printed circuits, flat or ribbon cables or like structures
- H01R12/65—Fixed connections for flexible printed circuits, flat or ribbon cables or like structures characterised by the terminal
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R35/00—Flexible or turnable line connectors, i.e. the rotation angle being limited
- H01R35/02—Flexible line connectors without frictional contact members
- H01R35/025—Flexible line connectors without frictional contact members having a flexible conductor wound around a rotation axis
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
- H01R43/20—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for assembling or disassembling contact members with insulating base, case or sleeve
- H01R43/24—Assembling by moulding on contact members
Definitions
- the invention relates to a two-row connector for a ribbon or foil cable, in particular an electrically conductive, one-piece flat part for producing the connector.
- the invention also relates to a method for producing the two-row connector, and a device for power transmission with a ribbon or foil cable and one or two connectors produced by the method.
- Ribbon or foil cables are used, among other things, when a large number of electrical connections are routed via an articulated mechanical connection, for example hinges or axes of rotation that are limited in their rotation by end stops, for example in the steering of vehicles.
- Ribbon cables are multi-core cables in which the cores are not arranged in a circular bundle in a round sheath, but rather run parallel to one another.
- the contacting of ribbon cables is usually done by means of so-called post connectors, which are preferably connected to the ribbon cable using insulation displacement technology, especially in the case of solid conductors.
- insulation displacement terminals of the connector matched to the spacing of the wires in the ribbon cable, are positioned on the wires and pressed in using a tool, the insulation displacement terminals severing the insulation of the wire and making the electrical contact.
- the insulation displacement technology is less suitable, especially for stranded conductors that allow greater flexibility and smaller bending radii.
- the contacting of the post plugs takes place perpendicular to the plane of the ribbon cable, so that the connectors attached to the ends of the ribbon cable have an installation space with a Need minimum height. Even if the ribbon cable is bent over directly at the outlet from the connector, the required installation space is considerably larger than the width of the connector itself due to the minimum bending radius that must be observed.
- Foil cables also known as Flat-Flex-Cable or FFC, are similar to flat-ribbon cables in the arrangement of the conductors next to each other in one plane, but do not use stranded wires, but rather conductive paths attached to a permanently flexible, electrically insulating carrier material, the ends of which are directly on or in intended Connectors can be attached or plugged in.
- Foil cables are particularly suitable for laying through very narrow openings and are also very insensitive to repeated bends above a minimum bending radius.
- changes in direction in one plane can also be achieved very easily with foil cables, provided that the kinks or folds required for this are not exposed to repeated mechanical kinking or folding movements.
- Foil cables are very well suited for electrical contacting of parts that are axially rotatable relative to one another, but do not require completely free rotation without an end stop on both sides.
- An example of such an application is the steering column of a vehicle, which has to be rotatable to the left or right to a limited extent from a central position.
- An airbag is often arranged in a steering wheel attached to the steering column, which airbag must be electrically connected to a corresponding control device in order to be triggered.
- control elements for different vehicle functions are arranged in many steering wheels, which are also electrically connected to the corresponding control units. Freedom of rotation could be achieved with slip ring contacts, but their absolute reliability, as is absolutely necessary for airbags, can be achieved over a long period of use, e.g. a service life of a vehicle that is often over 10 years, if at all only with great effort.
- slip rings are disadvantageous, especially at low currents, because of fluctuating contact resistances.
- the foil cable In the case of electrical connections that can be rotated to a limited extent by means of foil cables, the foil cable is wound in a spiral like a spring in a barrel of a clockwork mechanism. With a relative rotary movement of the two end points connected by the foil cable, the wound foil cable "breathes" like the spring of a clock. The turns are pulled together in one direction of rotation to a small diameter. In the other direction of rotation they open up again to a larger diameter. The conductors of a continuing line can be connected to the stripped conductors of the foil cable.
- Such an arrangement is, for example, from DE 41 19 769 A1 known.
- Another, related embodiment uses a flat ribbon cable that is wound in opposite directions and is arranged on an axis that is parallel to the axis of rotation of the mutually rotatable parts.
- the foil cable is wound up like a bifilar coil. If both ends are pulled in opposite directions, the diameter of the bifilar coil created by the winding is reduced. As a result of the elasticity of the foil cable, it winds up again when the tensile forces acting on its ends cease.
- Such an arrangement is also from the DE 41 19 769 A1 known.
- the present invention has the object of creating a two-row connector for connecting a ribbon cable or foil cable which overcomes or at least improves one or more of the problems mentioned at the beginning.
- the invention proposes, according to a first aspect, an electrically conductive, one-piece flat part which, according to a second aspect, is used in a method for producing a two-row connector.
- the invention proposes a two-row connector and a device for power transmission with a two-row connector according to the invention.
- An electrically conductive, one-piece flat part according to the first aspect for a plug with first and second contact pins arranged in two parallel rows and a connection area for a cable, the conductors of which lie next to one another in one plane, comprises a connecting element with a second side opposite a first side.
- the connecting element can for example be a rectangular frame, or a web-like or strip-like connecting element. Conductors which open into the first and second contact pins extend from the first and from the second side of the connecting element.
- the conductors lying on the opposite sides of the connecting element are connected to the connecting element offset from one another in such a way that the imaginary extension of a conductor on one side of the connecting element runs next to or between the connection points of one or two conductors with the connecting element on the opposite side.
- the first contact pins are connected to the first conductors extending from the first side of the connecting element via an offset area which compensates for the offset of the first and second conductors at their connection to the connecting element.
- two adjacent contact pins connected to the same side of the connecting element are connected to one another by webs at a distance from their ends.
- the distance from the ends of the contact pins is preferably selected so that the webs are located within a body of the plug when a connector is manufactured with the flat part, so that the sections of the conductors or contact pins immediately adjacent to the webs spatially are fixed, and the webs can be removed or interrupted, for example by punching out.
- the contact pins connected to the first side of the connecting element each run at a first distance from the connecting element at a first angle to the direction from which the conductors connected to them extend from the connecting element.
- the first distance can be different for each of the contact pins, so that the contact pins continue to lie in one plane.
- the contact pins connected to the second side of the connecting element each run at a second distance from the connecting element at a second angle to the direction from which the conductors connected to them extend from the connecting element.
- the second distance can be different for each of the contact pins, so that the contact pins continue to lie in one plane.
- the first and second distances between the contact pins connected to the first and the second side of the connecting element can also differ between two contact pins, the conductors of which alternate on different sides of the connecting element and which lie one above the other in a plug made using the flat part.
- the different distances can be due, among other things, to the fact that sections of the conductors extending from one side of the connecting element are brought out of the plane of the flat part into a plane running parallel to it by additional bending processes.
- the first and second angles are mirrored about a fold axis which is transverse to a direction in which the first and second conductors, respectively, extend from the connecting element.
- the folding axis can intersect the connecting element symmetrically in the middle between the first and the second side, but it can also be offset parallel thereto.
- the conductors can also run in other directions in sections between the connecting element and the contact pins, the conductors always running in one plane and apart from on the connecting element and are not in contact with one another at webs provided between the conductors in one or more configurations.
- the contact pins connected to the first side of the connecting element end at a greater distance from a third side connecting the first and second sides of the connecting element than the contact pins connected to the second side of the connecting element.
- This configuration also serves to compensate for the reduced distance between the contact pins and the connecting element during additional bending processes, by means of which sections of the conductors are brought out of the plane of the flat part into a plane running parallel to it, so that the rows of contact pins after the bending processes parallel to the manufacture of a connector and are of the same length.
- the flat part can be, for example, a part stamped from a sheet metal, a plate or a film, or a part produced by an additive method on a flat carrier, for example a printed or sintered part.
- the sheet metal can consist of a suitable electrically conductive metal or an electrically conductive alloy
- the plate or foil can consist of electrically conductive metals or alloys or electrically conductive plastics, or of planar structures composed of them.
- a composite structure comprises, in addition to one or two electrically conductive outer layers, an inner layer which is covered and connected to it and which itself consists of an electrically non-conductive material. In this way, two electrical connections can be made per contact.
- a connector produced in this way could, for example, be contacted from two sides with foil conductors, and thus enable the number of contacts to be doubled with the same space requirement for the connector.
- the flat part can preferably be cold formed and also after the forming still so dimensionally stable that the contact pins of a connector made with it retain their shape even after repeated plugging processes.
- a method for producing a flat part described above accordingly comprises the provision of a plate or sheet metal made of an electrically conductive material and the punching of the connecting element and the conductors and contact pins connected to it, the punching preferably taking place in a single step.
- An alternative method for producing a flat part described above accordingly comprises providing a flat carrier, applying an electrically conductive material in the form of the connecting element, the conductors and contact pins connected to it, and detaching the carrier from the flat part formed by the electrically conductive material .
- the application can take place in one or more layers, whereby individual of the several layers can be connected to one another by process steps adapted to the material used, for example drying, heating, cooling, cold welding, sintering, and the like.
- a method according to the second aspect for producing a two-row connector for a cable, the conductors of which lie next to one another in one plane, for example a ribbon or foil cable, comprises providing one of the flat parts described above, regardless of the type of its production.
- the conductors connected to the first side of the connecting element are then bent first in a first direction pointing out of the plane of the flat part.
- the conductors connected to the first side of the connecting element are also subjected to a second bending process, in which they are bent in a second direction opposite to the first, so that the contact pins connected to the conductors are in a plane lying to the plane of the flat part lie.
- the sequence of the bending processes is irrelevant.
- the conductors After the first and second bending process, which are also carried out simultaneously can take place, the conductors have a step, the contact pins of the conductors connected to the first and to the second side of the connecting element lying in parallel planes.
- the height of the step determines the distance between the two rows of contact pins. If the conductors connected to both sides of the connecting element are each bent in a step shape, the heights of the steps must be adapted to one another so that a desired distance between the two rows of contact pins is ultimately established.
- a first bending of the conductors connected to the first side of the connecting element in a first direction pointing out of the plane of the flat part is started. Subsequently or at the same time as this, the conductors connected to the second side of the connecting element are bent in a second direction pointing out of the plane of the flat part, which is opposite to the first direction.
- the distances between the two bending points are selected so that the contact pins of the first and second conductors have a desired distance from one another after the subsequent folding of the flat part.
- the bending processes are followed by a folding process in which the connecting element and / or the first and / or second conductors are folded along a folding axis which runs transversely to the direction in which the first and second conductors move away from the Extending connecting element, for example. At a right angle to it.
- the conductors extending from the first side of the connecting element lie next to or between the conductors extending from the second side of the connecting element in one plane, but without touching one another.
- the folding process can be divided into three or four bending processes, the respective bending axes or edges running parallel to the first or second side of the connecting element without one of the bending axes or edges dividing the connecting element symmetrically or having to lie within the connecting element at all.
- two of the bending processes bend the connecting element or the conductors in the same bending direction, and the third bending process bends the conductors connected to one side of the connecting element in the opposite bending direction.
- the conductors connected to the other side of the connector are not bent.
- two of the bending processes also bend the connecting element or the conductor in the same bending direction.
- the third and fourth bending processes bend the conductors emanating from the first and the second side of the connecting element in the opposite bending direction.
- the first and second sides of the connecting element approach each other - it is not necessary to touch the two sides at the end of the folding process.
- the resulting three-dimensional structure is overmolded or cast with an electrically insulating material.
- the electrically insulating material is sufficiently dimensionally stable, that is to say, for example, after cooling or hardening, the connecting element is separated and the webs connecting two adjacent contact pins are removed.
- a parallel displacement of the contact pins of the parallel rows with respect to one another depends on whether the lines leading to the contact pins already contain a corresponding lateral offset for correction in the flat part. As a result, all bends can take place along a common bending edge for all conductors connected to one side of the connecting element. A bend of each of the lines emanating from one side to eliminate the parallel shift would also be possible, but technically much more complex. If the contact pins of the two parallel rows are to be offset from one another, a correction of the offset is of course not necessary.
- the conductors connected to the second side of the connecting element are bent in accordance with those connected to the first side in corresponding first and second bending processes, for example if an offset of all contact pins relative to a plane is desired in which, after bending and folding the connection of the foil cable lies.
- the offset can bring both rows of the contact pins on the same side of the connection plane of the foil cable, or one row each on one of the two sides.
- the folded flat part is bent once or several times in an area in which the conductors connected to the first and second sides of the connecting element lie in one plane.
- a connection plane of the foil cable can run in a different direction than a direction in which the contact pins point.
- two parts of the body produced by the overmolding are separated, one of the two separated parts being movably supported along the conductors separated from the connecting element in a connection area of the plug.
- a clamping bracket that can be displaced parallel to the conductors located in the connection plane or the connection area of the plug can be molded onto the plug, by means of which a foil cable can be fixed in the plug and electrically contacted with the conductors.
- the separation can take place, for example, by separating connecting webs which connect the two parts after the overmolding.
- the connecting webs can, for example, be separated by machine, for example at the point in time at which the connecting element and the webs, which each connect two adjacent conductors, are removed or interrupted.
- a two-row plug according to a third aspect of the invention comprises one of the above-described, folded and bent flat parts, or the parts thereof remaining in the body of the plug after the overmolding and separation of the connecting element or the removal of the webs, and one by overmolding the flat part manufactured body.
- the plug has guide means in a connection plane in which the lines connected to the contact pins are located, which position conductors of a ribbon or foil cable provided for contacting the plug to the lines connected to the contact pins.
- the connection of the conductors of the ribbon or foil cable to the conductors of the plug can be made detachable by clamping or non-detachable by soldering or welding.
- the plug has a clamping means which is movably mounted parallel to the conductors separated from the connecting element. After the insertion of the ribbon or foil cable, the clamping means is pushed from an open position into a clamping position and fixes the ribbon or foil cable inserted into the connector.
- the clamping means can press exposed electrical contacts of the flat ribbon or foil cable onto exposed conductors in the connection area of the plug and thus establish electrical contact.
- the contact pins of the plug can lie in a plane parallel to the plane of the flat ribbon or foil cable or inclined with respect to this plane.
- the contact pins can point in the direction of the conductors of the flat ribbon or foil cable, or in a direction that points out of this, for example at right angles thereto.
- Corresponding mating contacts can be plugged onto the contact pins in order to establish the electrical connection to further lines or electrical devices.
- a device according to the invention for power transmission comprises at least one two-row plug according to the third aspect and a flat ribbon or foil cable connected to the plug in an electrically conductive manner.
- the ribbon cable or foil cable is in the form of a spiral.
- the ribbon cable or foil cable is wound up in a spiral shape in a bifilar winding.
- a two-row connector for a flat ribbon or foil cable can be produced in a simple manner, by means of which further lines or electrical devices can be connected in a simple manner. It is advantageous here that the flat part is in one piece and so there is no need to align and position two separate contact parts before the overmolding.
- the one-piece flat part gives the conductors and contacts greater stability during overmolding than could be achieved using separate parts. As a result, smaller conductor dimensions can also be used within the plug, since the webs which connect individual conductor pairs of the flat part to one another are only removed or interrupted after the overmolding, when the body has already spatially fixed the conductor.
- the injection mold can be designed more simply and the injection molding can be carried out in a single-stage injection molding process.
- a reproducible higher precision of the arrangement of the electrical contacts in the flat part according to the invention can be achieved.
- Figure 1 shows a schematic representation of two versions of a first exemplary flat part 100 according to the invention before forming.
- the flat part 100 has a connecting element 102, from the opposite sides of which first and second conductors 108, 110 extend.
- the difference between the in Figure 1a) and Figure 1b ) only consists in the fact that the connecting element 102 in Figure 1a ) is formed by a strip from which the conductors 108, 110 extend, while the connecting element 102 in FIG Figure 1b ) is formed by a frame that encloses a free interior space.
- Both versions offer the same advantages, but the location of the bending points can vary between the versions.
- only one folding axis 120 is shown by way of example, along or around which the flat part 100 is folded in order to obtain a conductor part of a two-row connector.
- first and second conductors 108, 110 open into first and second contact pins 112, 114, which are connected to webs 122, 124 to increase stability during processing.
- the lateral offset of the conductors lying opposite one another on the two sides of the connecting element is compensated for again by an offset section 132, so that the contact pins in the connector produced using the flat part 100 are again on top of one another.
- FIG. 2 shows a second exemplary flat part 100 according to the invention for a two-row plug 200 before forming.
- Flat part 100 has a connecting element 102 with a first and a second side 104, 106, from which first conductors 108 and second conductors 110 extend.
- the ends of the first and second conductors 108, 110 form first and second contact pins 112, 114.
- the first and second conductors 108, 110 are offset on the opposite first and second sides 104, 106 of the connecting element 102 so that the imaginary extension of a first conductor 108 extends beyond the connecting element 102 next to or between the connections of the second conductors 110 to the connecting element. In the figure this is indicated by the dashed lines which extend from the first conductors over the connecting element.
- the first contact pins 112 run at a first angle to the direction from which the first conductors 108 connected to them extend from the connecting element 102.
- the second contact pins 114 run at a second angle to the direction from which the second conductors 110 connected to them extend from the connecting element 102.
- the first and the second angle are mirrored on an axis 120 symmetrically intersecting the connecting element 102 in the middle between the first and the second side 104, 106.
- the first and second angles are right angles, but it is easy to imagine choosing other angles depending on the requirements of the connector and its installation location.
- Two adjacent first and second contact pins 112, 114, respectively, are connected to webs 122, 124 at a distance from their ends.
- the webs 122, 124 increase the stability of the flat part in subsequent processing steps; they are removed in one of the last processing steps, just like the connecting element 102.
- the contact pins 112 connected to the first side 104 of the connecting element 102 end at a greater distance from a third side 130 of the connecting element 102 than the contact pins 114 connected to the second side 106. This is indicated by the auxiliary lines in the figure 126, 128 indicated, as well as the intermediate arrow indicating the difference.
- the different distance between the ends of the first and second contact pins 112, 114 stems from the fact that at least the conductors arranged on one side of the connecting element have to be bent at two points so that the contact pins lie in a plane lying parallel to the plane of the connecting element After the processing steps, there are two parallel rows of contact pins, the ends of which lie in one plane. The step resulting from the bends requires correspondingly longer conductor sections between the connecting element 102 and the contact pins.
- FIG. 11 shows a perspective illustration of the flat part 100 from FIG Figure 2 after a first processing step 302 ( Figure 22 ) of a procedure 300 ( Figure 22 ) for producing a two-row plug 200.
- first processing step 302 Figure 22
- procedure 300 Figure 22
- the first contact pins 112 are bent by 90 ° out of the plane of the flat part 100 during a first bending process, so that they now point obliquely downward out of the plane of the drawing.
- the bending point lies between the webs 122 and a section 132 of the first conductor 108 connected to the first side 104 of the connecting element 102, which causes the comb-like offset of the first and second conductors 108, 110 after the connecting element has been folded 102 compensates again, so that the first and the second contact pins 112, 114 are aligned in parallel rows with one another.
- Section 132 is in the in Figure 3 The perspective shown can only be seen clearly at the edge and is therefore additionally highlighted with the dashed oval that is shown in Figure 1 is shown accordingly. The direction of bending is indicated by the arrow in this and the following figures.
- FIG. 11 shows a perspective illustration of the flat part 100 from FIG Figure 2 after a second processing step 304 ( Figure 22 ) of procedure 300 ( Figure 22 ) for the production of a two-row plug 200.
- this processing step the conductors were bent in a second bending process 108 in a direction opposite to the first bend, so that the first contact pins 112 are now in a plane parallel to the plane of the Flat part 100 run.
- the conductor sections 132 can also be seen again, on which the contact pins 112 are laterally offset.
- FIG. 11 shows a perspective illustration of the flat part 100 from FIG Figure 2 Figure 2 after a third processing step 302a ( Figure 22 ) of procedure 300 ( Figure 22 ) for producing a two-row plug 200.
- the conductors 110 were bent in a third bending process in a direction corresponding to the second bend, so that the second contact pins 114 point obliquely away from the viewer into the plane of the image.
- FIG. 11 shows a perspective illustration of the flat part 100 from FIG Figure 2 after a fourth processing step 304a ( Figure 22 ) of procedure 300 ( Figure 22 ) for the production of a two-row plug 200.
- this processing step the conductors 110 were bent in a fourth bending process in a direction corresponding to the first bend, so that the second contact pins 114 now run in a plane parallel to the plane of the flat part 100.
- FIG. 11 shows a perspective illustration of the flat part 100 from FIG Figure 2 after a first substep of a fifth processing step 306 ( Figure 22 ) of procedure 300 ( Figure 22 ) for the production of a two-row connector 200.
- this processing step which represents a first step of folding the connecting element 102, the first conductors 108 on the first side 104 of the connecting element 102 are bent away from the viewer into the image plane.
- FIG. 11 shows a perspective illustration of the flat part 100 from FIG Figure 2 after a second substep of the fifth processing step 306 ( Figure 22 ) of procedure 300 ( Figure 22 ) for producing a two-row connector 200.
- this processing step which represents a second step of folding the connecting element 102
- the connecting element 102 is bent in a direction opposite to the direction of bending of the first step of folding.
- the connecting element 102 is attached to the connecting webs between the first side 104 and the second side 106 bent so that the first conductors 108 and the second conductors 110 run in planes approximately perpendicular to one another.
- FIG. 11 shows a perspective illustration of the flat part 100 from FIG Figure 2 after a third substep of the fifth processing step 306 ( Figure 22 ) of procedure 300 ( Figure 22 ) for producing a two-row plug 200.
- this processing step which represents a third step in the folding of the connecting element 102, the second conductors 110 are bent away from the viewer towards the image plane.
- FIG. 11 shows a perspective illustration of the flat part 100 from FIG Figure 2 after a fourth substep of the fifth processing step 306 ( Figure 22 ) of procedure 300 ( Figure 22 ) for producing a two-row connector 200.
- this processing step which represents a fourth step of folding the connecting element 102
- the connecting element 102 is finally bent so that the first side 104 and the second side 106 of the connecting element 102 approach one another, and the first conductor 108 and the second conductor 110 lie alternately next to each other in one plane.
- the first and second contact pins 112, 114 are arranged in two parallel rows to one another.
- FIG. 11 shows a representation of the flat part 100 from FIG Figure 10 from a different perspective.
- the first and the second conductors 108, 110 lie in one plane, and that the first contact pins 112 and the second contact pins 114 are arranged one above the other in two parallel planes.
- the conductor section 132 of the first conductors 108 offset the first contact pins 112 laterally in such a way that they are each arranged exactly over the second contact pins 114.
- FIG. 11 shows a representation of the flat part 100 from FIG Figure 10 from another perspective. It can also be seen in this view that the first and second conductors 108, 110 lie in one plane, and that the first contact pins 112 and second contact pins 114 are arranged one above the other in two parallel planes.
- FIG. 11 shows a perspective illustration of the flat part 100 from FIG Figure 2 after a sixth processing step 312 ( Figure 22 ) of procedure 300 ( Figure 22 ) for the production of a two-row connector 200.
- the flat part 100 is bent out of the image plane towards the viewer in the area in which the first conductors 108 and the second conductors 110 lie alternately next to one another in one plane, so that the two parallel rows of contact pins 112, 114 no longer run in planes which are parallel to the plane in which the first conductors 108 and second conductors 110 extend from the connecting element 102.
- the dash-dotted line indicates the axis along which the bend took place.
- FIG. 11 shows a representation of the flat part 100 from FIG Figure 13 from a different perspective.
- the part with the first and second contact pins 112, 114 bent out of the plane of the first and second conductors 108, 100 is bent away from the viewer.
- the dash-dotted line indicates the axis along which the bend took place.
- FIG. 11 shows a perspective illustration of the flat part 100 from FIG Figure 2 after a seventh processing step 308 of the method 300 for producing a two-row connector 200.
- the flat part is off Figure 12 encapsulated with an electrically non-conductive material, for example plastic.
- the first and second contact pins 112, 114 and the connecting element 102 have remained free, as well as window 134 between the contact pins, a window 136 in the area in which the first and second conductors 108, 110 lie alternately next to one another in one plane, and two notches 138 next to the first and second conductors 108, 110.
- a guide or clamping part 140 is connected to the body 144 of the plug 200 by only two narrow connecting webs 142.
- FIG. 11 shows a perspective illustration of a detail of the flat part 100 from FIG Figure 2 manufactured connector 200 after an eighth processing step 310 ( Figure 22 ) of procedure 300 ( Figure 22 ).
- the connecting element 102 has been separated from the first and second conductors 108, 110.
- an in Foil cable not shown in the figure, are inserted into the plug, the conductor tracks of which correspond to the first and second conductors 108, 110.
- the conductor tracks of the foil cable can be electrically connected to the first and second conductors 108, 110, for example by soldering or welding.
- An electrical connection between the conductor tracks of the foil cable and the first and second conductors 108, 110 can also be established by pressing against one another.
- This in Figure 15 The detail shown is from the in Figure 14 not visible from the rear.
- FIG. 14 shows a representation of another detail of the using the flat part 100 from FIG Figure 2 manufactured connector 200 after the eighth processing step 310 ( Figure 22 ) of procedure 300 ( Figure 22 ).
- the webs lying between adjacent contact pins are interrupted by the window 134 so that the contact pins are no longer electrically connected to one another.
- the webs can be interrupted, for example, by punching tools which are passed through the windows 134 of the body 144.
- Figure 18 shows an illustration of the using the flat part from Figure 2 manufactured connector 200 from a first perspective. This illustration clearly shows how the contact pins run parallel to a plane that is slightly tilted with respect to the conductors 108, 110.
- Figures 19 to 21 show representations of the plug 200 from further perspectives.
- the connecting element 102 is shown as a substantially rectangular part with four sides which enclose a free interior space. It is also possible to use the connecting element as in Figure 1a ) shown merely as a strip connecting all conductors 108, 110 without a free interior space, the first side 104 and the second side 106 then lying on two sides of the same strip. The bending processes carried out within the connecting element 102 during the folding would in this case take place in the area of the conductors 108, 110. The first conductors 108 and / or the second conductors 110 are then expediently made correspondingly longer.
- FIG. 3 shows a schematic flow diagram of a method 300 according to the invention for producing a two-row plug 200 using a flat part 100 according to the invention.
- the individual method steps have already been described with reference to FIG Figures 1 to 15 are described in detail, so that only a brief summary is provided here.
- step 301 the flat part 100 according to the invention is first provided.
- step 302 in a first bending process at least the conductors 108 connected to the first side 104 of the connecting element 102 are bent at a third distance from the connecting element 102 in a first direction pointing out of the plane of the flat part 100.
- step 304 in a second bending process, at least the conductors 108 connected to the first side 104 of the connecting element 102 are bent at a fourth distance from the connecting element 102 in a direction opposite to the first bending direction, so that first contact pins 112 of the first conductors 108 in a parallel to the plane of the flat part 100 pointing second direction.
- the distance between the third and the fourth distance determines a height of the step created by the two bending processes and thereby ultimately the distance between the parallel rows of contact pins of the connector produced by the present method.
- the contact pins point out of the plane of the flat part with only one bend each, for example at a right angle to it.
- the first conductors would only be bent in a first bending process 302, and the second conductors correspondingly in a first bending process 302a.
- the optional bending process of the second conductor is shown in the figure as step 302a with a dashed border.
- the connecting element 102 is then folded along a folding axis 120 which intersects the connecting element symmetrically in the middle between the first and the second side, so that the first and the second side 104, 106 of the connecting element 102 approach one another and those of the First conductor 108 extending from the first side 104 of the connecting element 102 next to or between the second conductors 110 extending from the second side 106 of the connecting element 102 lie in a plane without touching one another.
- the folding can include several separate bending processes along different bending axes which are symmetrical or asymmetrical to the folding axis 120.
- step 308 the folded flat part 100 is encapsulated with an electrically insulating material.
- step 310 the connecting element 102 is severed and the webs 122, 124 are removed or severed.
- the folded flat part 100 can be subjected to one or more bending processes in an area in which the conductors 108, 110 connected to the first and second sides 104, 106 of the connecting element 102 lie in one plane.
- the contact pins can point in a direction which points out of the direction of the plane in which the conductors 108, 110 connected to the first and second sides 104, 106 of the connecting element 102 lie.
- a part 140 of the body 144 produced by overmolding the folded flat part 100 is separated from the latter.
- the separated part 140 is mounted longitudinally displaceably along the conductors 108, 110 separated from the connecting element 102 in a connection area of the plug 200 and can, for example, form a clamping part by means of which the ribbon or foil cable can be connected to the plug 200.
- FIG 23 a schematic flow diagram of a method 400 for producing a flat part 100 according to the invention is shown.
- the arrangement of the conductors 108, 110, the contact pins 112, 114 and the connecting element 102 has previously been determined according to the requirements of the plug.
- a plate or sheet metal made of an electrically conductive material is provided in step 402a, which is punched in the subsequent step 402b with a die that maps the previously determined arrangement of the conductors, the contact pins and the connecting element to one another accordingly .
- a flat carrier is provided in step 402b, to which an electrically conductive material in the previously defined shape of the flat part is applied in one or more layers in step 404b.
- the carrier is then detached from the flat part formed by the applied electrically conductive material.
- FIG. 24 shows a first schematic representation of an application of a device according to the invention for power transmission with a ribbon or foil cable and one or two plugs 200 produced using the flat part 100 according to the invention.
- the figure shows two circular walls 1 of a housing 2 of an electrical device.
- This device can, for example, be a control device built into the steering wheel of a motor vehicle.
- To power an electronics 3 of the device the same is connected to the battery 4 of the motor vehicle.
- the battery 4 is connected via an electrical line 5 to a terminal 6 designed as a fixed point.
- the electronics 3 are connected to a terminal 8 via an electrical line 7 connected, which is movable in the direction of the double arrow 9.
- a ribbon or foil cable 10 with several conductors is connected between the two end points 6 and 8.
- the lines 5 and 7 are "continuing lines" that are to be connected to the flat ribbon or foil cable 10.
- the ribbon or foil cable 10 can according to Fig. 24 be arranged between the two end points 6 and 8 in several turns, so in the manner of a barrel of clocks. Although the number of revolutions of a steering wheel is limited to a few revolutions, a larger number of turns can be provided for the ribbon cable or foil cable 10. The rotary movement of the end point 8 is then not significantly noticeable for a single turn of the flat ribbon or foil cable 10. Only the diameter of the coil consisting of all turns of the ribbon or foil cable 10 is reduced or increased. Ribbon or foil cable 10 is preferably equipped with flat conductors. This embodiment of the ribbon or foil cable 10 is particularly thin and therefore takes up very little space. In principle, however, the ribbon or foil cable 10 could also have round conductors.
- the ribbon cable or foil cable changes direction approximately in the middle and is arranged as a part leading back and forth in a spiral between the walls of the housing.
- the point at which the direction changes is shifted accordingly.
- the outwardly extending section rolls off the inner wall when it is rotated, so that the reversal point is displaced.
- Such an arrangement is also referred to as a U-turn clock spring.
- Ribbon or foil cable 10 can, as in Figure 25 shown, be wound as a bifilar coil 12 between the two end points 6 and 8.
- the ribbon or foil cable 10 is bent approximately in its center, so that a reversal point 13 results. From there, the ribbon cable or foil cable 10 is wound in two layers.
- the diameter of the bifilar coil 6 in the starting position of the device is expediently chosen so that it is equal to the shortest distance between the two end points 6 and 8 from one another or less than this distance.
- the ribbon or foil cable is provided with a connector 200 according to the invention at at least one of the two end points 6 and 8 in order to enable connection to further cables or lines or electrical devices.
- a connector 200 according to the invention at at least one of the two end points 6 and 8 in order to enable connection to further cables or lines or electrical devices.
- ⁇ u> List of reference symbols ⁇ /u> 1 Wall 134 window 2 casing 136 window 3 electronics 138 score 4th battery 140 Guide or clamping part 5 electrical line 142 Connecting bridge 6th Terminal 144 Body 7th electrical line 200 plug 8th Terminal 300 Procedure 9 Double arrow 301-314 Procedural steps 10 Ribbon or foil cables 400 Procedure 12 Bifilar coil 402-406 Procedural steps 13 Reversal point 100 Flat part 102 Connecting element 104 first page 106 second page 108 first ladder 110 second ladder 112 first contact pins 114 second contact pins 116a-116e first intervals 118a-118e second intervals 120 axis 122 web 124 web 126 Auxiliary line 128 Aux
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Abstract
Ein elektrisch leitfähiges, einteiliges Flachteil (100) für einen Stecker mit in zwei parallelen Reihen angeordneten Kontaktstiften (112, 114) und einem Anschlussbereich für ein Kabel, umfasst ein Verbindungselement (102). Von der ersten und von der zweiten Seite des Verbindungselements aus erstrecken sich in den ersten bzw. zweiten Kontaktstiften (112, 114) mündende Leiter (108, 110), die auf den gegenüberliegenden Seiten Verbindungselements (102) liegenden Leiter (108, 110) so gegeneinander versetzt mit dem Verbindungselement (102) verbunden sind, dass die gedachte gerade Verlängerung eines Leiters (108, 110) auf der einen Seite des Verbindungselements (102) neben einem oder zwischen zwei Leitern (108, 110) auf der gegenüberliegenden Seite des Verbindungselements (102) verläuft. Die ersten Kontaktstifte (112) sind mit den sich von der ersten Seite des Verbindungselements (102) aus erstreckenden ersten Leitern (108) über einen Versatzbereich (132) verbunden, welcher den Versatz der ersten und zweiten Leiter (108, 110) an dem Verbindungselement (102) ausgleicht.An electrically conductive, one-piece flat part (100) for a plug with contact pins (112, 114) arranged in two parallel rows and a connection area for a cable, comprises a connecting element (102). From the first and from the second side of the connecting element, conductors (108, 110) which open into the first and second contact pins (112, 114) extend, the conductors (108, 110) lying on the opposite sides of the connecting element (102) so are connected to the connecting element (102) offset from one another, so that the imaginary straight extension of a conductor (108, 110) on one side of the connecting element (102) next to one or between two conductors (108, 110) on the opposite side of the connecting element ( 102) runs. The first contact pins (112) are connected to the first conductors (108) extending from the first side of the connecting element (102) via an offset region (132) which determines the offset of the first and second conductors (108, 110) on the connecting element (102) compensates.
Description
Die Erfindung betrifft einen zweireihigen Stecker für ein Flachband- oder Folienkabel, insbesondere ein elektrisch leitendes, einteiliges Flachteil zur Herstellung des Steckers. Die Erfindung betrifft außerdem ein Verfahren zur Herstellung des zweireihigen Steckers, und eine Vorrichtung zur Stromübertragung mit einem Flachband- oder Folienkabel und einem oder zwei nach dem Verfahren hergestellten Steckern.The invention relates to a two-row connector for a ribbon or foil cable, in particular an electrically conductive, one-piece flat part for producing the connector. The invention also relates to a method for producing the two-row connector, and a device for power transmission with a ribbon or foil cable and one or two connectors produced by the method.
Flachband- oder Folienkabel werden unter anderem dann verwendet, wenn eine Vielzahl von elektrischen Verbindungen über eine artikulierte mechanische Verbindung geführt werden, bspw. Scharniere oder von Endanschlägen in ihrer Drehung begrenzte Drehachsen, etwa in Lenkungen von Fahrzeugen. Flachbandkabel sind mehradrige Kabel, in denen die Adern nicht kreisförmig gebündelt in einer runden Hülle angeordnet sind, sondern parallel nebeneinander geführt sind.Ribbon or foil cables are used, among other things, when a large number of electrical connections are routed via an articulated mechanical connection, for example hinges or axes of rotation that are limited in their rotation by end stops, for example in the steering of vehicles. Ribbon cables are multi-core cables in which the cores are not arranged in a circular bundle in a round sheath, but rather run parallel to one another.
Die Kontaktierung von Flachbandkabeln erfolgt in der Regel mittels sogenannter Pfostensteckverbinder, die insbesondere bei massiven Leitern vorzugsweise in Schneidklemmtechnik mit dem Flachbandkabel verbunden werden. Dabei werden auf den Abstand der Adern im Flachbandkabel abgestimmte Schneidklemmen des Steckverbinders zu den Adern positioniert und mittels eines Werkzeugs eingepresst, wobei die Schneidklemmen die Isolierung der Ader durchtrennen und den elektrischen Kontakt herstellen. Gerade bei Litzenleitern, die eine höhere Biegsamkeit und kleinere Biegeradien ermöglichen, ist die Schneidklemmtechnik weniger gut geeignet. Die Kontaktierung der Pfostenstecker erfolgt senkrecht zu der Ebene des Flachbandkabels, so dass die an den Enden des Flachbandkabels angebrachten Stecker einen am Einbauort einen Bauraum mit einer Mindesthöhe benötigen. Selbst wenn das Flachbandkabel unmittelbar am Austritt aus dem Stecker umgebogen wird ist der benötigte Bauraum durch den einzuhaltenden minimalen Biegeradius um einiges größer als die Breite des Steckers selbst.The contacting of ribbon cables is usually done by means of so-called post connectors, which are preferably connected to the ribbon cable using insulation displacement technology, especially in the case of solid conductors. In this case, insulation displacement terminals of the connector, matched to the spacing of the wires in the ribbon cable, are positioned on the wires and pressed in using a tool, the insulation displacement terminals severing the insulation of the wire and making the electrical contact. The insulation displacement technology is less suitable, especially for stranded conductors that allow greater flexibility and smaller bending radii. The contacting of the post plugs takes place perpendicular to the plane of the ribbon cable, so that the connectors attached to the ends of the ribbon cable have an installation space with a Need minimum height. Even if the ribbon cable is bent over directly at the outlet from the connector, the required installation space is considerably larger than the width of the connector itself due to the minimum bending radius that must be observed.
Folienkabel, auch als Flat-Flex-Cable oder FFC bekannt, ähneln Flachbandkabeln in der Anordnung der Leiter in einer Ebene nebeneinander, nutzen aber keine Litzen, sondern auf einem dauerhaft flexiblen, elektrisch isolierenden Trägermaterial aufgebrachte Leiterbahnen, deren Enden direkt auf oder in dafür bestimmte Steckverbinder auf- oder eingesteckt werden können. Folienkabel sind besonders gut geeignet für eine Verlegung durch sehr schmale Öffnungen hindurch, und sind auch gegenüber wiederholten Biegungen oberhalb eines Mindest-Biegeradius sehr unempfindlich. Zudem lassen sich mit Folienkabeln auch Richtungswechsel in einer Ebene sehr leicht erreichen, sofern die dazu erforderlichen Knick- bzw. Faltstellen nicht wiederholten mechanischen Knick- oder Faltbewegungen ausgesetzt sind.Foil cables, also known as Flat-Flex-Cable or FFC, are similar to flat-ribbon cables in the arrangement of the conductors next to each other in one plane, but do not use stranded wires, but rather conductive paths attached to a permanently flexible, electrically insulating carrier material, the ends of which are directly on or in intended Connectors can be attached or plugged in. Foil cables are particularly suitable for laying through very narrow openings and are also very insensitive to repeated bends above a minimum bending radius. In addition, changes in direction in one plane can also be achieved very easily with foil cables, provided that the kinks or folds required for this are not exposed to repeated mechanical kinking or folding movements.
Folienkabel sind sehr gut für elektrische Kontaktierungen von Teilen geeignet, die axial gegeneinander verdrehbar gelagert sind, aber keine völlig freie Drehbarkeit ohne einen Endanschlag zu beiden Seiten erfordern.Foil cables are very well suited for electrical contacting of parts that are axially rotatable relative to one another, but do not require completely free rotation without an end stop on both sides.
Ein Beispiel für eine solche Anwendung ist die Lenksäule eines Fahrzeugs, die aus einer Mittellage heraus begrenzt nach links oder rechts drehbar sein muss. In einem an der Lenksäule angebrachten Lenkrad ist häufig ein Airbag angeordnet, welcher zum Auslösen elektrisch mit einem entsprechenden Steuergerät verbunden sein muss. Außerdem sind in vielen Lenkrädern Bedienelemente für unterschiedliche Fahrzeugfunktionen angeordnet, die ebenfalls elektrisch mit den entsprechenden Steuergeräten verbunden sind. Eine freie Drehbarkeit wäre mit Schleifringkontakten erzielbar, jedoch ist deren absolute Zuverlässigkeit, wie sie etwa bei Airbags unbedingt erforderlich ist, über einen langen Nutzungszeitraum, z.B. eine Nutzungsdauer eines Fahrzeugs, die häufig über 10 Jahren liegt, wenn überhaupt nur unter hohem Aufwand zu erreichen. Neben dem Verschleiß sind Schleifringe insbesondere bei niedrigen Stromstärken wegen schwankender Übergangswiderstände nachteilig.An example of such an application is the steering column of a vehicle, which has to be rotatable to the left or right to a limited extent from a central position. An airbag is often arranged in a steering wheel attached to the steering column, which airbag must be electrically connected to a corresponding control device in order to be triggered. In addition, control elements for different vehicle functions are arranged in many steering wheels, which are also electrically connected to the corresponding control units. Freedom of rotation could be achieved with slip ring contacts, but their absolute reliability, as is absolutely necessary for airbags, can be achieved over a long period of use, e.g. a service life of a vehicle that is often over 10 years, if at all only with great effort. In addition to wear, slip rings are disadvantageous, especially at low currents, because of fluctuating contact resistances.
Bei elektrischen Anschlüssen gegeneinander begrenzt verdrehbarer Bauteile mittels Folienkabeln ist das Folienkabel ähnlich einer Feder in einem Federhaus eines Uhrwerks spiralförmig aufgewickelt. Bei einer relativen Drehbewegung der beiden durch das Folienkabel verbundenen Endstellen "atmet" das aufgewickelte Folienkabel wie die Feder einer Uhr. Die Windungen werden in der einen Drehrichtung auf einen kleinen Durchmesser zusammengezogen. Sie gehen in der anderen Drehrichtung wieder auf einen größeren Durchmesser auf. An die abisolierten Leiter des Folienkabels können die Leiter einer weiterführenden Leitung angeschlossen sein. Eine solche Anordnung ist bspw. aus der
Eine andere, verwandte Ausführung nutzt ein gegenläufig spiralförmig aufgewickeltes Flachbandkabel, das auf einer zur Drehachse der gegeneinander verdrehbaren Teile parallelen Achse angeordnet ist. Das Folienkabel ist dabei nach Art einer Bifilarspule aufgewickelt. Wenn an deren beiden Enden in entgegengesetzter Richtung gezogen wird, verkleinert die durch das Wickeln entstandene Bifilarspule ihren Durchmesser. Infolge der Elastizität des Folienkabels wickelt es sich wieder auf, wenn die an dessen Enden angreifenden Zugkräfte fortfallen. Eine solche Anordnung ist ebenfalls aus der
Bei den bekannten Anwendungen von Flachband- oder Folienkabeln bleibt die Kontaktierung an den Enden ein fortbestehendes Problem, insbesondere wenn an die in einer Ebene parallel angeordneten Leiter des Flachband- oder Folienkabels ein zweireihiger Stecker angeschlossen werden soll.In the known applications of ribbon or foil cables, contact at the ends remains a problem, especially when a two-row connector is to be connected to the conductors of the ribbon or foil cable arranged in parallel in one plane.
Hiervon ausgehend hat die vorliegende Erfindung die Aufgabe, einen zweireihigen Stecker zum Anschluss eines Flachband- oder Folienkabels zu schaffen, der eines oder mehrere der eingangs genannten Probleme überwindet oder zumindest verbessert.Proceeding from this, the present invention has the object of creating a two-row connector for connecting a ribbon cable or foil cable which overcomes or at least improves one or more of the problems mentioned at the beginning.
Zur Lösung dieser Aufgabe schlägt die Erfindung nach einem ersten Aspekt ein elektrisch leitfähiges, einteiliges Flachteil vor, das gemäß einem zweiten Aspekt in einem Verfahren zur Herstellung eines zweireihigen Steckers genutzt wird. In einem dritten Aspekt schlägt die Erfindung einen zweireihigen Stecker sowie eine Vorrichtung zur Stromübertragung mit einem erfindungsgemäßen zweireihigen Stecker vor.To solve this problem, the invention proposes, according to a first aspect, an electrically conductive, one-piece flat part which, according to a second aspect, is used in a method for producing a two-row connector. In a third aspect, the invention proposes a two-row connector and a device for power transmission with a two-row connector according to the invention.
Ein elektrisch leitfähiges, einteiliges Flachteil nach dem ersten Aspekt für einen Stecker mit in zwei parallelen Reihen angeordneten ersten und zweiten Kontaktstiften und einem Anschlussbereich für ein Kabel, dessen Leiter in einer Ebene nebeneinander liegen, umfasst ein Verbindungselement mit einer einer ersten Seite gegenüberliegenden zweiten Seite. Das Verbindungselement kann beispielsweise ein rechteckiger Rahmen sein, oder ein steg- oder streifenartiges Verbindungselement. Von der ersten und von der zweiten Seite des Verbindungselements aus erstrecken sich in den ersten bzw. zweiten Kontaktstiften mündende Leiter. Dabei sind die auf den gegenüberliegenden Seiten des Verbindungselements liegenden Leiter so gegeneinander versetzt mit dem Verbindungselement verbunden, dass die gedachte Verlängerung eines Leiters auf der einen Seite des Verbindungselements neben oder zwischen den Verbindungsstellen eines oder zweier Leiter mit dem Verbindungselement auf der gegenüberliegenden Seite verläuft. Die ersten Kontaktstifte sind mit den sich von der ersten Seite des Verbindungselements aus erstreckenden ersten Leitern über einen Versatzbereich verbunden, welcher den Versatz der ersten und zweiten Leiter an deren Verbindung mit dem Verbindungselement ausgleicht.An electrically conductive, one-piece flat part according to the first aspect for a plug with first and second contact pins arranged in two parallel rows and a connection area for a cable, the conductors of which lie next to one another in one plane, comprises a connecting element with a second side opposite a first side. The connecting element can for example be a rectangular frame, or a web-like or strip-like connecting element. Conductors which open into the first and second contact pins extend from the first and from the second side of the connecting element. The conductors lying on the opposite sides of the connecting element are connected to the connecting element offset from one another in such a way that the imaginary extension of a conductor on one side of the connecting element runs next to or between the connection points of one or two conductors with the connecting element on the opposite side. The first contact pins are connected to the first conductors extending from the first side of the connecting element via an offset area which compensates for the offset of the first and second conductors at their connection to the connecting element.
Bei einer oder mehreren Ausgestaltungen sind jeweils zwei benachbarte, mit derselben Seite des Verbindungselements verbundene Kontaktstifte in einem Abstand von deren Enden miteinander durch Stege verbunden. Der Abstand von den Enden der Kontaktstifte ist vorzugsweise so gewählt, dass die Stege bei der Herstellung eines Steckers mit dem Flachteil innerhalb eines Korpus des Steckers liegen, so dass die den Stegen unmittelbar benachbarten Abschnitte der Leiter bzw. Kontaktstifte räumlich fixiert sind, und die Stege bspw. durch Ausstanzen entfernbar oder unterbrechbar sind.In one or more configurations, two adjacent contact pins connected to the same side of the connecting element are connected to one another by webs at a distance from their ends. The distance from the ends of the contact pins is preferably selected so that the webs are located within a body of the plug when a connector is manufactured with the flat part, so that the sections of the conductors or contact pins immediately adjacent to the webs spatially are fixed, and the webs can be removed or interrupted, for example by punching out.
Bei einer oder mehreren Ausgestaltungen verlaufen die mit der ersten Seite des Verbindungselements verbundenen Kontaktstifte jeweils in einem ersten Abstand von dem Verbindungselement in einem ersten Winkel zu der Richtung, aus der sich die mit ihnen verbundenen Leiter von dem Verbindungselement aus erstrecken. Der erste Abstand kann für jeden der Kontaktstifte unterschiedlich sein, so dass die Kontaktstifte weiterhin in einer Ebene liegen. Entsprechend verlaufen die mit der zweiten Seite des Verbindungselements verbundenen Kontaktstifte jeweils in einem zweiten Abstand von dem Verbindungselement in einem zweiten Winkel zu der Richtung, aus der sich die mit ihnen verbundenen Leiter von dem Verbindungselement aus erstrecken. Auch hier kann der zweite Abstand für jeden der Kontaktstifte unterschiedlich sein, so dass die Kontaktstifte weiterhin in einer Ebene liegen. Die ersten und zweiten Abstände der mit der ersten und der zweiten Seite des Verbindungselements verbundenen Kontaktstifte können sich auch zwischen zwei Kontaktstiften unterscheiden, deren Leiter jeweils im Wechsel an unterschiedlichen Seiten des Verbindungselements aufeinanderfolgen, und die in einem unter Verwendung des Flachteils hergestellten Stecker übereinander liegen. Die unterschiedlichen Abstände können unter anderem daher rühren, dass Abschnitte der sich von einer Seite des Verbindungselements erstreckenden Leiter durch zusätzliche Biegevorgänge aus der Ebene des Flachteils heraus in eine parallel dazu verlaufende Ebene gebracht werden.In one or more configurations, the contact pins connected to the first side of the connecting element each run at a first distance from the connecting element at a first angle to the direction from which the conductors connected to them extend from the connecting element. The first distance can be different for each of the contact pins, so that the contact pins continue to lie in one plane. Correspondingly, the contact pins connected to the second side of the connecting element each run at a second distance from the connecting element at a second angle to the direction from which the conductors connected to them extend from the connecting element. Here, too, the second distance can be different for each of the contact pins, so that the contact pins continue to lie in one plane. The first and second distances between the contact pins connected to the first and the second side of the connecting element can also differ between two contact pins, the conductors of which alternate on different sides of the connecting element and which lie one above the other in a plug made using the flat part. The different distances can be due, among other things, to the fact that sections of the conductors extending from one side of the connecting element are brought out of the plane of the flat part into a plane running parallel to it by additional bending processes.
Der erste und der zweite Winkel sind an einer Faltachse gespiegelt, welche quer zu einer Richtung verläuft, in der sich die ersten bzw. zweiten Leiter von dem Verbindungselement aus erstrecken. Die Faltachse kann das das Verbindungselement in der Mitte zwischen der ersten und der zweiten Seite symmetrisch schneiden, sie kann aber auch parallel dazu versetzt sein.The first and second angles are mirrored about a fold axis which is transverse to a direction in which the first and second conductors, respectively, extend from the connecting element. The folding axis can intersect the connecting element symmetrically in the middle between the first and the second side, but it can also be offset parallel thereto.
Die Leiter können zwischen dem Verbindungselement und den Kontaktstiften auch abschnittsweise in anderen Richtungen verlaufen, wobei die Leiter stets in einer Ebene verlaufen und außer an dem Verbindungselement und an in einer oder mehreren Ausgestaltungen zwischen den Leitern vorgesehenen Stegen nicht miteinander in Kontakt stehen.The conductors can also run in other directions in sections between the connecting element and the contact pins, the conductors always running in one plane and apart from on the connecting element and are not in contact with one another at webs provided between the conductors in one or more configurations.
Bei einer oder mehreren Ausgestaltungen enden die mit der ersten Seite des Verbindungselements verbundenen Kontaktstifte in einem größeren Abstand zu einer dritten, die erste und die zweite Seite des Verbindungselements verbindenden Seite, als die mit der zweiten Seite des Verbindungselements verbundenen Kontaktstifte. Auch diese Ausgestaltung dient dazu, den bei zusätzlichen Biegevorgängen, mittels derer Abschnitte der Leiter aus der Ebene des Flachteils heraus in eine parallel dazu verlaufende Ebene gebracht werden, verringerten Abstand der Kontaktstifte von dem Verbindungselement auszugleichen, so dass die Reihen der Kontaktstifte nach den Biegevorgängen bei der Herstellung eines Steckers parallel liegen und gleich lang sind.In one or more configurations, the contact pins connected to the first side of the connecting element end at a greater distance from a third side connecting the first and second sides of the connecting element than the contact pins connected to the second side of the connecting element. This configuration also serves to compensate for the reduced distance between the contact pins and the connecting element during additional bending processes, by means of which sections of the conductors are brought out of the plane of the flat part into a plane running parallel to it, so that the rows of contact pins after the bending processes parallel to the manufacture of a connector and are of the same length.
Es ist natürlich bei jeder der hierein beschriebenen Ausgestaltungen möglich, einzelne Kontaktstifte gezielt länger oder kürzer als andere auszuführen, um voreilende oder nacheilende Kontakte zu erhalten, also Kontakte, die beim Zusammenführen von Stecker und Buchse eine elektrische Verbindung vor oder nach anderen Kontakten herstellen.It is of course possible with each of the configurations described here to make individual contact pins longer or shorter than others in a targeted manner in order to obtain leading or trailing contacts, i.e. contacts that establish an electrical connection before or after other contacts when the plug and socket are brought together.
Das Flachteil kann beispielsweise ein aus einem Blech, einer Platte oder einer Folie gestanztes Teil sein, oder ein durch ein additives Verfahren auf einem flachen Träger hergestelltes Teil, bspw. ein Druck- oder Sinterteil. Das Blech kann hierbei aus einem geeigneten elektrisch leitfähigen Metall oder einer elektrisch leitfähigen Legierung bestehen, die Platte oder Folie können aus elektrisch leitfähigen Metallen bzw. Legierungen oder elektrisch leitfähigen Kunststoffen bestehen, oder aus daraus zusammengesetzten planen Strukturen. Eine zusammengesetzte Struktur umfasst neben einer oder zwei elektrisch leitfähigen äußeren Schichten eine damit belegte und verbundene, selbst aus einem elektrisch nicht leitfähigen Material bestehende innere Schicht. Auf diese Weise lassen sich pro Kontakt zwei elektrische Verbindungen herstellen. Ein hiermit hergestellter Stecker könnte bspw. von zwei Seiten mit Folienleitern kontaktiert werden, und so eine Verdoppelung der Anzahl der Kontakte bei gleichem Raumbedarf des Steckers ermöglichen. Das Flachteil ist dabei vorzugsweise kalt umformbar und auch nach dem Umformen noch so formstabil, dass die Kontaktstifte eines damit hergestellten Steckers auch bei mehrmaligen Steckvorgängen ihre Form behalten.The flat part can be, for example, a part stamped from a sheet metal, a plate or a film, or a part produced by an additive method on a flat carrier, for example a printed or sintered part. The sheet metal can consist of a suitable electrically conductive metal or an electrically conductive alloy, the plate or foil can consist of electrically conductive metals or alloys or electrically conductive plastics, or of planar structures composed of them. A composite structure comprises, in addition to one or two electrically conductive outer layers, an inner layer which is covered and connected to it and which itself consists of an electrically non-conductive material. In this way, two electrical connections can be made per contact. A connector produced in this way could, for example, be contacted from two sides with foil conductors, and thus enable the number of contacts to be doubled with the same space requirement for the connector. The flat part can preferably be cold formed and also after the forming still so dimensionally stable that the contact pins of a connector made with it retain their shape even after repeated plugging processes.
Ein Verfahren zur Herstellung eines vorstehend beschriebenen Flachteils umfasst entsprechend das Bereitstellen einer Platte bzw. eines Blechs aus einem elektrisch leitfähigen Material und das Stanzen des Verbindungselements und der daran angeschlossenen Leiter und Kontaktstifte, wobei das Stanzen vorzugsweise in einem einzigen Schritt erfolgt.A method for producing a flat part described above accordingly comprises the provision of a plate or sheet metal made of an electrically conductive material and the punching of the connecting element and the conductors and contact pins connected to it, the punching preferably taking place in a single step.
Ein alternatives Verfahren zur Herstellung eines vorstehend beschriebenen Flachteils umfasst entsprechend das Bereitstellen eines ebenen Trägers, das Aufbringen eines elektrisch leitfähigen Materials in der Form des Verbindungselements, der daran angeschlossenen Leiter und Kontaktstifte, sowie das Ablösen des Trägers von dem durch das elektrisch leitfähige Material gebildete Flachteil. Das Aufbringen kann dabei in einer oder mehreren Schichten erfolgen, wobei einzelne der mehreren Schichten durch an das jeweils verwendete Material angepasste Prozessschritte miteinander verbunden werden können, bspw. Trocknen, Erhitzen, Erkalten, Kaltverschweißen, Sintern, und dergleichen.An alternative method for producing a flat part described above accordingly comprises providing a flat carrier, applying an electrically conductive material in the form of the connecting element, the conductors and contact pins connected to it, and detaching the carrier from the flat part formed by the electrically conductive material . The application can take place in one or more layers, whereby individual of the several layers can be connected to one another by process steps adapted to the material used, for example drying, heating, cooling, cold welding, sintering, and the like.
Ein Verfahren gemäß dem zweiten Aspekt zu Herstellung eines zweireihigen Steckers für ein Kabel, dessen Leiter in einer Ebene nebeneinander liegen, bspw. ein Flachband- oder Folienkabel, umfasst das Bereitstellen eines der vorstehend beschriebenen Flachteile, unabhängig von der Art seiner Herstellung.A method according to the second aspect for producing a two-row connector for a cable, the conductors of which lie next to one another in one plane, for example a ribbon or foil cable, comprises providing one of the flat parts described above, regardless of the type of its production.
Bei einer ersten Variante folgt nun ein erstes Biegen der mit der ersten Seite des Verbindungselements verbundenen Leiter in eine aus der Ebene des Flachteils herausweisenden ersten Richtung. Bei dieser Variante werden die mit der ersten Seite des Verbindungselements verbundenen Leiter außerdem einem zweiten Biegevorgang unterworfen, bei dem sie in eine zweite, der ersten entgegengesetzten Richtung gebogen werden, so dass die mit den Leitern verbundenen Kontaktstifte in einer zu der Ebene des Flachteils liegenden Ebene liegen. Die Reihenfolge der Biegevorgänge ist dabei unerheblich. Nach dem ersten und zweiten Biegevorgang, die auch simultan erfolgen können, weisen die Leiter eine Stufe auf, wobei die Kontaktstifte der an die erste und an die zweite Seite des Verbindungselements angeschlossenen Leiter in parallelen Ebenen liegen. Wenn nur die an einer Seite des Verbindungselements angeschlossenen Leiter stufenförmig gebogen werden bestimmt die Höhe der Stufe den Abstand der zwei Reihen von Kontaktstiften voneinander. Wenn die an beiden Seiten des Verbindungselements angeschlossenen Leiter jeweils stufenförmig gebogen werden, sind die Höhen der Stufen aneinander anzupassen, damit sich letztlich ein gewünschter Abstand der zwei Reihen von Kontaktstiften voneinander einstellt.In a first variant, the conductors connected to the first side of the connecting element are then bent first in a first direction pointing out of the plane of the flat part. In this variant, the conductors connected to the first side of the connecting element are also subjected to a second bending process, in which they are bent in a second direction opposite to the first, so that the contact pins connected to the conductors are in a plane lying to the plane of the flat part lie. The sequence of the bending processes is irrelevant. After the first and second bending process, which are also carried out simultaneously can take place, the conductors have a step, the contact pins of the conductors connected to the first and to the second side of the connecting element lying in parallel planes. If only the conductors connected to one side of the connecting element are bent stepwise, the height of the step determines the distance between the two rows of contact pins. If the conductors connected to both sides of the connecting element are each bent in a step shape, the heights of the steps must be adapted to one another so that a desired distance between the two rows of contact pins is ultimately established.
Auch bei einer zweiten Variante wird mit einem ersten Biegen der mit der ersten Seite des Verbindungselements verbundenen Leiter in eine aus der Ebene des Flachteils herausweisenden ersten Richtung begonnen. Im Anschluss oder zeitgleich dazu werden die mit der zweiten Seite des Verbindungselements verbundenen Leiter in eine aus der Ebene des Flachteils herausweisenden zweiten Richtung gebogen, welche der ersten Richtung entgegengesetzt ist. Die Abstände der beiden Biegestellen sind dabei so gewählt, dass die Kontaktstifte der ersten und zweiten Leiter nach dem anschließenden Falten des Flachteils einen gewünschten Abstand voneinander haben.In a second variant, too, a first bending of the conductors connected to the first side of the connecting element in a first direction pointing out of the plane of the flat part is started. Subsequently or at the same time as this, the conductors connected to the second side of the connecting element are bent in a second direction pointing out of the plane of the flat part, which is opposite to the first direction. The distances between the two bending points are selected so that the contact pins of the first and second conductors have a desired distance from one another after the subsequent folding of the flat part.
Unabhängig von der Variante folgt im Anschluss an die Biegevorgänge ein Faltvorgang, bei dem das Verbindungselement und/oder die ersten und/oder zweiten Leiter entlang einer Faltachse gefaltet werden, welche quer zu der Richtung verläuft, in der sich die ersten und zweiten Leiter von dem Verbindungselement aus erstrecken, bspw. in einem rechten Winkel dazu. Nach dem Falten liegen die sich von der ersten Seite des Verbindungselements aus erstreckenden Leiter neben oder zwischen den sich von der zweiten Seite des Verbindungselements aus erstreckenden Leitern in einer Ebene, ohne sich jedoch zu berühren. Der Faltvorgang kann in drei oder vier Biegevorgänge unterteilt sein, deren jeweilige Biegeachsen oder -kanten parallel zu der ersten bzw. zweiten Seite des Verbindungselements verlaufen, ohne dass eine der Biegeachsen oder -kanten das Verbindungselement symmetrisch teilt oder überhaupt innerhalb des Verbindungselements liegen müsste.Regardless of the variant, the bending processes are followed by a folding process in which the connecting element and / or the first and / or second conductors are folded along a folding axis which runs transversely to the direction in which the first and second conductors move away from the Extending connecting element, for example. At a right angle to it. After folding, the conductors extending from the first side of the connecting element lie next to or between the conductors extending from the second side of the connecting element in one plane, but without touching one another. The folding process can be divided into three or four bending processes, the respective bending axes or edges running parallel to the first or second side of the connecting element without one of the bending axes or edges dividing the connecting element symmetrically or having to lie within the connecting element at all.
Bei einer Ausgestaltung mit drei Biegevorgängen biegen zwei der Biegevorgänge das Verbindungselement bzw. die Leiter in dieselbe Biegerichtung, und der dritte Biegevorgang biegt die mit einer Seite des Verbindungselements verbundenen Leiter in die entgegengesetzte Biegerichtung. Die an der anderen Seite des Verbindungselements angeschlossenen Leiter werden nicht gebogen.In an embodiment with three bending processes, two of the bending processes bend the connecting element or the conductors in the same bending direction, and the third bending process bends the conductors connected to one side of the connecting element in the opposite bending direction. The conductors connected to the other side of the connector are not bent.
Bei einer Ausgestaltung mit vier Biegevorgängen biegen ebenfalls zwei der Biegevorgänge das Verbindungselement bzw. die Leiter in dieselbe Biegerichtung. Der dritte und der vierte Biegevorgang biegen die von der ersten und von der zweiten Seite des Verbindungselements ausgehenden Leiter jeweils in die entgegengesetzte Biegerichtung.In an embodiment with four bending processes, two of the bending processes also bend the connecting element or the conductor in the same bending direction. The third and fourth bending processes bend the conductors emanating from the first and the second side of the connecting element in the opposite bending direction.
Sofern die Biegeachsen eines oder zweier Biegevorgänge des Faltvorgangs innerhalb des Verbindungselements liegen nähern sich die erste und die zweite Seite des Verbindungselements einander an - eine Berührung der beiden Seiten am Ende des Faltvorgangs ist nicht nötig.If the bending axes of one or two bending processes of the folding process lie within the connecting element, the first and second sides of the connecting element approach each other - it is not necessary to touch the two sides at the end of the folding process.
Nach dem Biegen bzw. Falten des Flachteils wird die so entstandene dreidimensionale Struktur mit einem elektrisch isolierenden Material umspritzt oder umgossen. Sobald das elektrisch isolierende Material ausreichend formstabil vorliegt, also bspw. nach dem Abkühlen oder Aushärten, wird das Verbindungselement abgetrennt und die jeweils zwei benachbarten Kontaktstifte verbindenden Stege entfernt.After the flat part has been bent or folded, the resulting three-dimensional structure is overmolded or cast with an electrically insulating material. As soon as the electrically insulating material is sufficiently dimensionally stable, that is to say, for example, after cooling or hardening, the connecting element is separated and the webs connecting two adjacent contact pins are removed.
An dieser Stelle ist anzumerken, dass eine parallele Verschiebung der Kontaktstifte der parallelen Reihen gegeneinander davon abhängt, ob die zu den Kontaktstiften führenden Leitungen bereits im Flachteil einen entsprechenden seitlichen Versatz zur Korrektur enthalten. Hierdurch können alle Biegungen jeweils für alle mit einer Seite des Verbindungselements verbundenen Leiter entlang einer gemeinsamen Biegekante erfolgen. Eine Biegung jeder einzelnen der von einer Seite ausgehenden Leitungen zur Beseitigung der parallelen Verschiebung wäre zwar ebenfalls möglich, technisch aber ungleich aufwendiger. Wenn die Kontaktstifte der beiden parallelen Reihen gegeneinander versetzt sein sollen ist eine Korrektur des Versatzes natürlich nicht erforderlich.At this point it should be noted that a parallel displacement of the contact pins of the parallel rows with respect to one another depends on whether the lines leading to the contact pins already contain a corresponding lateral offset for correction in the flat part. As a result, all bends can take place along a common bending edge for all conductors connected to one side of the connecting element. A bend of each of the lines emanating from one side to eliminate the parallel shift would also be possible, but technically much more complex. If the contact pins of the two parallel rows are to be offset from one another, a correction of the offset is of course not necessary.
Bei einer oder mehreren Ausgestaltungen des Verfahrens werden die mit der zweiten Seite des Verbindungselements verbundenen Leiter entsprechend denen mit der ersten Seite verbundenen in entsprechenden ersten und zweiten Biegevorgängen gebogen, bspw. wenn ein Versatz aller Kontaktstifte gegenüber einer Ebene gewünscht ist, in der nach dem Biegen und Falten der Anschluss des Folienkabels liegt. Der Versatz kann dabei beide Reihen der Kontaktstifte auf die gleiche Seite der Anschlussebene des Folienkabels bringen, oder jeweils eine Reihe auf eine der beiden Seiten.In one or more refinements of the method, the conductors connected to the second side of the connecting element are bent in accordance with those connected to the first side in corresponding first and second bending processes, for example if an offset of all contact pins relative to a plane is desired in which, after bending and folding the connection of the foil cable lies. The offset can bring both rows of the contact pins on the same side of the connection plane of the foil cable, or one row each on one of the two sides.
Bei einer oder mehreren Ausgestaltungen des Verfahrens wird das gefaltete Flachteil in einem Bereich, in dem die mit der ersten und der zweiten Seite des Verbindungselements verbundenen Leiter in einer Ebene liegen, ein- oder mehrmals gebogen. Hierdurch kann bspw. eine Anschlussebene des Folienkabels in einer anderen Richtung verlaufen als eine Richtung, in der die Kontaktstifte weisen.In one or more refinements of the method, the folded flat part is bent once or several times in an area in which the conductors connected to the first and second sides of the connecting element lie in one plane. In this way, for example, a connection plane of the foil cable can run in a different direction than a direction in which the contact pins point.
Mehrere der vorstehend mit Bezug auf eine oder mehrere Ausgestaltungen beschriebenen Biegevorgänge können zeitgleich und/oder in anderer Reihenfolge ausgeführt werden; die Bezeichnung der Biegevorgänge mit Zählvariablen setzt keine Reihenfolge oder zeitlich aufeinanderfolgende Biegevorgänge voraus.Several of the bending processes described above with reference to one or more configurations can be carried out simultaneously and / or in a different order; the designation of the bending processes with counter variables does not require any sequence or chronological successive bending processes.
Bei einer oder mehreren Ausgestaltungen folgt nach dem Umspritzen eine Separation zweier Teile des durch das Umspritzen hergestellten Korpus, wobei eines der beiden separierten Teile entlang der von dem Verbindungselement abgetrennten Leitern in einem Anschlussbereich des Steckers beweglich gelagert ist. Dadurch kann in einem einzigen Spritzvorgang bspw. ein parallel zu den in der Anschlussebene bzw. dem Anschlussbereich des Steckers liegenden Leitern verschiebbarer Klemmbügel an den Stecker angespritzt werden, mittels dessen ein Folienkabel in dem Stecker fixiert und elektrisch mit den Leitern kontaktiert werden kann. Die Separation kann bspw. durch Trennen von Verbindungsstegen erfolgen, welche die beiden Teile nach dem Umspritzen verbinden. Die Verbindungsstege können bspw. maschinell getrennt werden, etwa zu dem Zeitpunkt, zu dem das Verbindungselement und die Stege, die jeweils zwei benachbarte Leiter miteinander verbinden entfernt bzw. unterbrochen werden. Es ist jedoch auch möglich, die Verbindungsstege sehr dünn auszuführen, so dass sie aufgrund einer auf den Klemmbügel einwirkenden Kraft abbrechen oder reißen und den Klemmbügel freigeben.In one or more embodiments, after the overmolding, two parts of the body produced by the overmolding are separated, one of the two separated parts being movably supported along the conductors separated from the connecting element in a connection area of the plug. As a result, in a single injection process, for example, a clamping bracket that can be displaced parallel to the conductors located in the connection plane or the connection area of the plug can be molded onto the plug, by means of which a foil cable can be fixed in the plug and electrically contacted with the conductors. The separation can take place, for example, by separating connecting webs which connect the two parts after the overmolding. The connecting webs can, for example, be separated by machine, for example at the point in time at which the connecting element and the webs, which each connect two adjacent conductors, are removed or interrupted. However, it is also possible to make the connecting webs very thin, so that they break off or tear due to a force acting on the clamping bracket and release the clamping bracket.
Ein zweireihiger Stecker gemäß einem dritten Aspekt der Erfindung umfasst eines der vorstehend beschriebenen, gefalteten und gebogenen Flachteile, bzw. die im Korpus des Steckers nach dem Umspritzen und Abtrennen des Verbindungselements bzw. dem Entfernen der Stege verbleibenden Teile davon, und einen durch Umspritzen des Flachteils hergestellten Korpus.A two-row plug according to a third aspect of the invention comprises one of the above-described, folded and bent flat parts, or the parts thereof remaining in the body of the plug after the overmolding and separation of the connecting element or the removal of the webs, and one by overmolding the flat part manufactured body.
Bei einer Ausgestaltung weist der Stecker in einer Anschlussebene, in welcher die mit den Kontaktstiften verbundenen Leitungen liegen, Führungsmittel auf, welche Leiter eines zur Kontaktierung mit dem Stecker vorgesehenes Flachband- oder Folienkabels zu den mit den Kontaktstiften verbundenen Leitungen positionieren. Der Anschluss der Leiter des Flachband- oder Folienkabels an die Leiter des Steckers kann lösbar durch Klemmen oder unlösbar durch Löten oder Schweißen erfolgen.In one embodiment, the plug has guide means in a connection plane in which the lines connected to the contact pins are located, which position conductors of a ribbon or foil cable provided for contacting the plug to the lines connected to the contact pins. The connection of the conductors of the ribbon or foil cable to the conductors of the plug can be made detachable by clamping or non-detachable by soldering or welding.
Bei einer Variante der Ausgestaltung weist der Stecker ein Klemmmittel auf, das parallel zu den von dem Verbindungselement abgetrennten Leitern beweglich gelagert ist. Das Klemmmittel wird nach dem Einführen des Flachband- oder Folienkabels von einer offenen Position in eine Klemmposition geschoben und fixiert das in den Stecker eingeführte Flachband- oder Folienkabel. Bei Ausgestaltungen dieser Variante kann das Klemmmittel freiliegende elektrische Kontakte des Flachband- oder Folienkabels auf im Anschlussbereich des Steckers freiliegende Leiter pressen und so einen elektrischen Kontakt herstellen.In a variant of the embodiment, the plug has a clamping means which is movably mounted parallel to the conductors separated from the connecting element. After the insertion of the ribbon or foil cable, the clamping means is pushed from an open position into a clamping position and fixes the ribbon or foil cable inserted into the connector. In embodiments of this variant, the clamping means can press exposed electrical contacts of the flat ribbon or foil cable onto exposed conductors in the connection area of the plug and thus establish electrical contact.
Die Kontaktstifte des Steckers können in einer zu der Ebene des Flachband- oder Folienkabels parallelen oder gegenüber dieser geneigten Ebene liegen. Die Kontaktstifte können dabei in Richtung der Leiter des Flachband- oder Folienkabels weisen, oder in einer Richtung, die aus dieser herausweist, bspw. rechtwinklig dazu.The contact pins of the plug can lie in a plane parallel to the plane of the flat ribbon or foil cable or inclined with respect to this plane. The contact pins can point in the direction of the conductors of the flat ribbon or foil cable, or in a direction that points out of this, for example at right angles thereto.
Auf die Kontaktstifte können entsprechende Gegenkontakte aufgesteckt werden, um den elektrischen Anschluss an weiterführende Leitungen oder elektrische Geräte herzustellen.Corresponding mating contacts can be plugged onto the contact pins in order to establish the electrical connection to further lines or electrical devices.
Eine erfindungsgemäße Vorrichtung zur Stromübertragung umfasst mindestens einen zweireihigen Stecker gemäß dem dritten Aspekt und ein mit dem Stecker elektrisch leitend verbundenes Flachband- oder Folienkabel.A device according to the invention for power transmission comprises at least one two-row plug according to the third aspect and a flat ribbon or foil cable connected to the plug in an electrically conductive manner.
Bei einer Ausgestaltung liegt das Flachband- oder Folienkabel spiralförmig aufgewickelt vor.In one embodiment, the ribbon cable or foil cable is in the form of a spiral.
Bei einer anderen Ausgestaltung liegt das Flachband- oder Folienkabel in einer Bifilarwicklung spiralförmig aufgewickelt vor.In another embodiment, the ribbon cable or foil cable is wound up in a spiral shape in a bifilar winding.
Mit dem erfindungsgemäßen Flachteil und Verfahren ist auf einfache Weise ein zweireihiger Stecker für ein Flachband- oder Folienkabel herstellbar, mittels dessen auf einfache Weise weiterführende Leitungen oder elektrische Geräte angeschlossen werden können. Vorteilhaft ist dabei, dass das Flachteil einteilig ist und so eine Ausrichtung und Positionierung zweier separater Kontaktteile vor dem Umspritzen entfällt. Das einteilige Flachteil verleiht den Leitern und Kontakten während des Umspritzens eine höhere Stabilität, als dies bei Verwendung separater Teile erreicht werden könnte. Dadurch sind auch kleinere Leiterabmessungen innerhalb des Steckers nutzbar, da die Stege, welche einzelne Leiterpaare des Flachteils miteinander verbinden, erst nach dem Umspritzen entfernt oder unterbrochen werden, wenn der Korpus die Leiter bereits räumlich fixiert.With the flat part and method according to the invention, a two-row connector for a flat ribbon or foil cable can be produced in a simple manner, by means of which further lines or electrical devices can be connected in a simple manner. It is advantageous here that the flat part is in one piece and so there is no need to align and position two separate contact parts before the overmolding. The one-piece flat part gives the conductors and contacts greater stability during overmolding than could be achieved using separate parts. As a result, smaller conductor dimensions can also be used within the plug, since the webs which connect individual conductor pairs of the flat part to one another are only removed or interrupted after the overmolding, when the body has already spatially fixed the conductor.
Zudem kann das Spritzwerkzeug einfacher gestaltet sein und das Umspritzen in einem einstufigen Spritzvorgang erfolgen. Außerdem ist eine reproduzierbar höhere Präzision der Anordnung der elektrischen Kontakte in dem unter Verwendung des erfindungsgemäßen Flachteils erreichbar.In addition, the injection mold can be designed more simply and the injection molding can be carried out in a single-stage injection molding process. In addition, a reproducible higher precision of the arrangement of the electrical contacts in the flat part according to the invention can be achieved.
Nachfolgend wird die Erfindung anhand einer Ausführungsform unter Bezugnahme auf die begleitenden Figuren exemplarisch näher erläutert. Alle Figuren sind rein schematisch und nicht maßstäblich. Es zeigen:
- Fig. 1
- eine schematische Darstellung zweier Versionen eines ersten exemplarischen erfindungsgemäßen Flachteils vor dem Umformen,
- Fig. 2
- ein zweites exemplarisches erfindungsgemäßes Flachteil für einen zweireihigen Stecker vor dem Umformen,
- Fig. 3
- eine perspektivische Darstellung des Flachteils aus
Figur 2 nach einem ersten Verarbeitungsschritt eines Verfahrens zur Herstellung eines zweireihigen Steckers, - Fig. 4
- eine perspektivische Darstellung des Flachteils aus
Figur 2 nach einem zweiten Verarbeitungsschritt des Verfahrens zur Herstellung eines zweireihigen Steckers, - Fig. 5
- eine perspektivische Darstellung des Flachteils aus
Figur 2 nach einem dritten Verarbeitungsschritt des Verfahrens zur Herstellung eines zweireihigen Steckers, - Fig. 6
- eine perspektivische Darstellung des Flachteils aus
Figur 2 nach einem vierten Verarbeitungsschritt des Verfahrens zur Herstellung eines zweireihigen Steckers, - Fig. 7
- eine perspektivische Darstellung des Flachteils aus
Figur 2 nach einem ersten Teilschritt eines fünften Verarbeitungsschritts des Verfahrens zur Herstellung eines zweireihigen Steckers, - Fig. 8
- eine perspektivische Darstellung des Flachteils aus
Figur 2 nach einem zweiten Teilschritt des fünften Verarbeitungsschritts des Verfahrens zur Herstellung eines zweireihigen Steckers, - Fig. 9
- eine perspektivische Darstellung des Flachteils aus
Figur 2 nach einem dritten Teilschritt des fünften Verarbeitungsschritts des Verfahrens zur Herstellung eines zweireihigen Steckers, - Fig. 10
- eine perspektivische Darstellung des Flachteils aus
Figur 2 nach einem vierten Teilschritt des fünften Verarbeitungsschritts des Verfahrens zur Herstellung eines zweireihigen Steckers, - Fig. 11
- eine Darstellung des Flachteils aus
Figur 10 aus einer anderen Perspektive, - Fig. 12
- eine Darstellung des Flachteils aus
Figur 10 aus einer weiteren Perspektive, - Fig. 13
- eine perspektivische Darstellung des Flachteils aus
Figur 2 nach einem sechsten Verarbeitungsschritt des Verfahrens zur Herstellung eines zweireihigen Steckers, - Fig. 14
- eine Darstellung des Flachteils aus
Figur 13 aus einer anderen Perspektive, - Fig. 15
- eine perspektivische Darstellung des Flachteils aus
Figur 2 nach einem siebten Verarbeitungsschritt des Verfahrens zur Herstellung eines zweireihigen Steckers, - Fig. 16
- eine perspektivische Darstellung eines Details des unter Verwendung des Flachteils aus
Figur 2 hergestellten Steckers nach einem achten Verarbeitungsschritt des Verfahrens, - Fig. 17
- eine perspektivische Darstellung eines anderen Details des unter Verwendung des Flachteils aus
Figur 2 hergestellten Steckers nach dem achten Verarbeitungsschritt des Verfahrens, - Fig. 18
- eine Darstellung des unter Verwendung des Flachteils aus
Figur 2 hergestellten Steckers aus einer ersten Perspektive, - Fig. 19-21
- Darstellungen des Steckers aus weiteren Perspektiven,
- Fig. 22
- ein schematisches Flussdiagramm des erfindungsgemäßen Verfahrens zur Herstellung eines zweireihigen Steckers unter Verwendung eines erfindungsgemäßen Flachteils,
- Fig. 23
- ein schematisches Flussdiagramm eines Verfahrens zur Herstellung eines erfindungsgemäßen Flachteils,
- Fig. 24
- eine erste schematische Darstellung einer Anwendung einer erfindungsgemäßen Vorrichtung zur Stromübertragung mit einem Flachband- oder Folienkabel und einem oder zwei unter Verwendung des erfindungsgemäßen Flachteils hergestellten Steckern, und
- Fig. 25
- eine zweite schematische Darstellung einer Anwendung einer erfindungsgemäßen Vorrichtung zur Stromübertragung mit einem Flachband- oder Folienkabel und einem oder zwei unter Verwendung des erfindungsgemäßen Flachteils hergestellten Steckern.
- Fig. 1
- a schematic representation of two versions of a first exemplary flat part according to the invention before forming,
- Fig. 2
- a second exemplary flat part according to the invention for a two-row plug before forming,
- Fig. 3
- a perspective view of the flat part
Figure 2 after a first processing step of a method for manufacturing a two-row connector, - Fig. 4
- a perspective view of the flat part
Figure 2 after a second processing step of the method for producing a two-row connector, - Fig. 5
- a perspective view of the flat part
Figure 2 after a third processing step of the method for manufacturing a two-row connector, - Fig. 6
- a perspective view of the flat part
Figure 2 after a fourth processing step of the method for producing a two-row connector, - Fig. 7
- a perspective view of the flat part
Figure 2 after a first sub-step of a fifth processing step of the method for producing a two-row connector, - Fig. 8
- a perspective view of the flat part
Figure 2 after a second sub-step of the fifth processing step of the method for producing a two-row connector, - Fig. 9
- a perspective view of the flat part
Figure 2 after a third sub-step of the fifth processing step of the method for producing a two-row connector, - Fig. 10
- a perspective view of the flat part
Figure 2 after a fourth sub-step of the fifth processing step of the method for producing a two-row connector, - Fig. 11
- a representation of the flat part
Figure 10 from a different perspective, - Fig. 12
- a representation of the flat part
Figure 10 from another perspective, - Fig. 13
- a perspective view of the flat part
Figure 2 after a sixth processing step of the method for producing a two-row connector, - Fig. 14
- a representation of the flat part
Figure 13 from a different perspective, - Fig. 15
- a perspective view of the flat part
Figure 2 after a seventh processing step of the method for producing a two-row connector, - Fig. 16
- a perspective view of a detail of using the flat part from
Figure 2 manufactured connector after an eighth processing step of the process, - Fig. 17
- a perspective view of another detail of the using the flat part from
Figure 2 manufactured connector after the eighth processing step of the process, - Fig. 18
- a representation of using the flat part
Figure 2 manufactured connector from a first perspective, - 19-21
- Representations of the connector from further perspectives,
- Fig. 22
- a schematic flow diagram of the method according to the invention for producing a two-row connector using a flat part according to the invention,
- Fig. 23
- a schematic flow diagram of a method for producing a flat part according to the invention,
- Fig. 24
- a first schematic representation of an application of a device according to the invention for power transmission with a Ribbon or foil cables and one or two plugs produced using the flat part according to the invention, and
- Fig. 25
- a second schematic representation of an application of a device according to the invention for power transmission with a ribbon or foil cable and one or two plugs produced using the flat part according to the invention.
Gleiche oder ähnliche Elemente sind in den Figuren mit gleichen oder ähnlichen Bezugszeichen versehen.The same or similar elements are provided with the same or similar reference symbols in the figures.
Bei beiden Versionen münden die ersten und zweiten Leiter 108, 110 in ersten und zweiten Kontaktstiften 112, 114, die zur Erhöhung der Stabilität während der Bearbeitung mit Stegen 122, 124 verbunden sind. Der seitliche Versatz der sich an den beiden Seiten des Verbindungselements gegenüberliegenden Leiter wird durch einen Versatzabschnitt 132 wieder ausgeglichen, so dass die Kontaktstifte in dem unter Verwendung des Flachteils 100 hergestellten Stecker wieder übereinander liegen.In both versions, the first and
Jeweils zwei benachbarte erste bzw. zweite Kontaktstifte 112, 114 sind von deren Enden beabstandet mit Stegen 122, 124 verbunden. Die Stege 122, 124 erhöhen die Stabilität des Flachteils bei nachfolgenden Verarbeitungsschritten, sie werden in einem der letzten Verarbeitungsschritte entfernt, genauso wie das Verbindungselement 102.Two adjacent first and second contact pins 112, 114, respectively, are connected to
Die mit der ersten Seite 104 des Verbindungselements 102 verbundenen Kontaktstifte 112 enden in einem größeren Abstand von einer dritten Seite 130 des Verbindungselements 102 als die mit der zweiten Seite 106 verbundenen Kontaktstifte 114. In der Figur ist dies durch die Hilfslinien 126, 128 angedeutet, sowie den dazwischen liegenden, die Differenz anzeigenden Pfeil. Der unterschiedliche Abstand der Enden der ersten und zweiten Kontaktstifte 112, 114 rührt daher, dass zumindest die an einer Seite des Verbindungselements angeordneten Leiter an zwei Stellen so gebogen werden müssen, dass die Kontaktstifte in einer zu der Ebene des Verbindungselements parallel liegenden Ebene liegen, damit nach den Verarbeitungsschritten zwei parallele Reihen von Kontaktstiften vorliegen, deren Enden in einer Ebene liegen. Die für die aus den Biegungen resultierende Stufe benötigt entsprechend längere Leiterabschnitte zwischen dem Verbindungselement 102 und den Kontaktstiften.The contact pins 112 connected to the
In den
In Schritt 304 werden in einem zweiten Biegevorgang zumindest die mit der ersten Seite 104 des Verbindungselements 102 verbundenen Leiter 108 in einem vierten Abstand von dem Verbindungselement 102 in eine der ersten Biegerichtung entgegengesetzte Richtung gebogen, so dass erste Kontaktstifte 112 der ersten Leiter 108 in einer parallel zu der Ebene des Flachteils 100 weisenden zweiten Richtung liegen. Die Distanz zwischen dem dritten und dem vierten Abstand bestimmt eine Höhe der durch die beiden Biegevorgänge entstandenen Stufe und dadurch letztlich den Abstand der parallelen Reihen von Kontaktstiften des nach dem vorliegenden Verfahren hergestellten Steckers.In
Je nach den Formerfordernissen des Steckers ist es möglich, nur die mit einer Seite des Verbindungselements 102 verbundenen Leiter in einen stufenförmigen Verlauf zu biegen, und die mit der anderen Seite des Verbindungselements verbundenen Leiter gerade zu lassen. Es ist jedoch auch möglich, die Leiter auf beiden Seiten des Verbindungselements 102 jeweils in einen stufenförmigen Verlauf zu biegen. Dann kann ein seitlicher Versatz der Kontaktstifte 112, 114 gegenüber einer Ebene eingestellt werden, in der sich die Leiter 108, 110 von dem Verbindungselement aus erstrecken. Jeweils eine Reihe von Kontaktstiften kann dann auf einer Seite der Ebene liegen, oder beide Reihen von Kontaktstiften können auf derselben Seite der Ebene liegen. Die optionalen zusätzlichen Biegevorgänge der auf der anderen Seite des Verbindungselements 102 verbundenen Leiter sind in der Figur als Schritte 302a, 304a mit gestrichelter Umrandung dargestellt.Depending on the shape requirements of the plug, it is possible to bend only the conductors connected to one side of the connecting
Es ist ebenfalls möglich, die Kontaktstifte mit nur jeweils einer Biegung aus der Ebene des Flachteils heraus weisen zu lassen, bspw. in einem rechten Winkel dazu. In diesem Fall würden die ersten Leiter nur in einem ersten Biegevorgang 302 gebogen werden, und die zweiten Leiter entsprechend in einem ersten Biegevorgang 302a. Der optionale Biegevorgang der zweiten Leiter ist in der Figur als Schritt 302a mit gestrichelter Umrandung dargestellt.It is also possible to have the contact pins point out of the plane of the flat part with only one bend each, for example at a right angle to it. In this case, the first conductors would only be bent in a
In Schritt 306 wird dann das Verbindungselement 102 entlang einer das Verbindungselement in der Mitte zwischen der ersten und der zweiten Seite symmetrisch schneidenden Faltachse 120 gefaltet, so dass die erste und die zweite Seite 104, 106 des Verbindungselements 102 sich aneinander annähern und die sich von der ersten Seite 104 des Verbindungselements 102 aus erstreckenden ersten Leiter 108 neben oder zwischen den sich von der zweiten Seite 106 des Verbindungselements 102 aus erstreckenden zweiten Leitern 110 in einer Ebene liegen, ohne sich zu berühren. Das Falten kann dabei mehrere separate Biegevorgänge entlang unterschiedlicher Biegeachsen umfassen, welche symmetrisch oder unsymmetrisch zu der Faltachse 120 liegen.In
In Schritt 308 folgt das Umspritzen des gefalteten Flachteils 100 mit einem elektrisch isolierenden Material.In
In Schritt 310 wird das Verbindungselement 102 abgetrennt und die Stege 122, 124 entfernt bzw. durchtrennt.In
In einem vor dem Umspritzen liegenden optionalen Schritt 312 kann das gefaltete Flachteil 100 in einem Bereich einem oder mehreren Biegevorgängen unterworfen werden, in dem die mit der ersten und der zweiten Seite 104, 106 des Verbindungselements 102 verbundenen Leiter 108, 110 in einer Ebene liegen. Dadurch können die Kontaktstifte in eine Richtung weisen, die aus der Richtung der Ebene herausweist, in welcher die mit der ersten und der zweiten Seite 104, 106 des Verbindungselements 102 verbundenen Leiter 108, 110 liegen.In an
In einem abschließenden optionalen Schritt 314 wird ein Teil 140 des durch Umspritzen des gefalteten Flachteils 100 hergestellten Korpus 144 von diesem separiert. Das separierte Teil 140 ist entlang der von dem Verbindungselement 102 abgetrennten Leiter 108, 110 in einem Anschlussbereich des Steckers 200 längs verschiebbar gelagert und kann bspw. ein Klemmteil bilden, mittels dessen das Flachband- oder Folienkabel an dem Stecker 200 angeschlossen werden kann.In a final,
In
In einer ersten Variante des Verfahrens wird in Schritt 402a eine Platte oder ein Blech aus einem elektrisch leitfähigen Material bereitgestellt, das in dem nachfolgenden Schritt 402b mit einer Stanzform gestanzt wird, welche die zuvor festgelegte Anordnung der Leiter, der Kontaktstifte und des Verbindungselements zueinander entsprechend abbildet.In a first variant of the method, a plate or sheet metal made of an electrically conductive material is provided in
In einer zweiten Variante des Verfahrens wird in Schritt 402b ein ebener Träger bereitgestellt, auf den in Schritt 404b ein elektrisch leitfähiges Material in der zuvor festgelegten Form des Flachteils in einer oder mehreren Schichten aufgebracht wird. In Schritt 406 wird dann der Träger von dem durch das aufgebrachte elektrisch leitfähige Material gebildeten Flachteil gelöst.In a second variant of the method, a flat carrier is provided in
In
Das Flachband- oder Folienkabel 10 kann gemäß
Bei einer nicht in der Figur gezeigten Variante wechselt das Flachband- oder Folienkabel etwa in der Mitte die Richtung und ist als hin und zurück führendes Teil spiralförmig zwischen den Wandungen des Gehäuses angeordnet. Bei einer Drehung der Endstelle verlagert sich die Stelle, an der die Richtung wechselt entsprechend. Anders ausgedrückt rollt der außen verlaufende Abschnitt bei einer Drehung auf der inneren Wandung ab, so dass sich die Umkehrstelle verlagert. Eine solche Anordnung wird auch als U-Turn-Clockspring bezeichnet.In a variant not shown in the figure, the ribbon cable or foil cable changes direction approximately in the middle and is arranged as a part leading back and forth in a spiral between the walls of the housing. When the end point is rotated, the point at which the direction changes is shifted accordingly. In other words, the outwardly extending section rolls off the inner wall when it is rotated, so that the reversal point is displaced. Such an arrangement is also referred to as a U-turn clock spring.
Flachband- oder Folienkabel 10 kann, wie in
Bei beiden der in den Figuren gezeigten Vorrichtungen zur Stromübertragung ist das Flachband- oder Folienkabel an zumindest einer der beiden Endstellen 6 und 8 mit einem erfindungsgemäßen Stecker 200 versehen, um den Anschluss an weiterführende Kabel bzw. Leitungen oder elektrische Geräte zu ermöglichen.
Claims (12)
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Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
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EP19315086.9A EP3772784B1 (en) | 2019-08-08 | 2019-08-08 | Two-row connector for a strip or film cable, method for producing the same, and power transmission device |
US16/986,487 US11239621B2 (en) | 2019-08-08 | 2020-08-06 | Double-row plug for a ribbon or foil cable, method for the production thereof, and apparatus for the transmission of current |
Applications Claiming Priority (1)
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EP19315086.9A EP3772784B1 (en) | 2019-08-08 | 2019-08-08 | Two-row connector for a strip or film cable, method for producing the same, and power transmission device |
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EP3772784A1 true EP3772784A1 (en) | 2021-02-10 |
EP3772784B1 EP3772784B1 (en) | 2022-12-21 |
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US20210044068A1 (en) | 2021-02-11 |
EP3772784B1 (en) | 2022-12-21 |
US11239621B2 (en) | 2022-02-01 |
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