EP3772784A1 - Two-row connector for a strip or film cable, method for producing the same, and power transmission device - Google Patents

Abstract

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

area

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.

background

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. 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.

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.

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. 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.

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.

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.

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.

Summary of the invention

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

In one embodiment, the ribbon cable or foil cable is in the form of a spiral.

In another embodiment, the ribbon cable or foil cable is wound up in a spiral shape in a bifilar winding.

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.

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.

Brief description of the drawing

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.

In the following, the invention is explained in more detail using an embodiment with reference to the accompanying figures. All figures are purely schematic and not to scale. Show it:

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.

The same or similar elements are provided with the same or similar reference symbols in the figures.

Execution example

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. In the figure, 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.

In both versions, the 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.

Figure 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. From the respective first distances 116a-116e from the connecting element 102, 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. From the respective first distances 118a-118e 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. In the example shown in the figure, 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.

Figure 3 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. For the sake of clarity, only the elements relevant for understanding are provided with reference symbols in this and the following figures. In the first processing step, 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. In the exemplary flat part shown in the figure, 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.

Figure 4 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. In 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. In this figure, the conductor sections 132 can also be seen again, on which the contact pins 112 are laterally offset.

Figure 5 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. In this processing step, 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.

Figure 6 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. In 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.

Figure 7 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. In 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.

Figure 8 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. In 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.

Figure 9 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. In 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.

Figure 10 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. In 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. It can already be seen clearly in the figure that the first and second contact pins 112, 114 are arranged in two parallel rows to one another.

Figure 11 FIG. 11 shows a representation of the flat part 100 from FIG Figure 10 from a different perspective. In this view it can be clearly seen that 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. In this figure it can also be clearly seen how 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.

Figure 12 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.

Figure 13 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. In this processing step, 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.

Figure 14 FIG. 11 shows a representation of the flat part 100 from FIG Figure 13 from a different perspective. In this illustration, 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. As in Figure 13 the dash-dotted line indicates the axis along which the bend took place.

Figure 15 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. In this processing step, 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.

Figure 16 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 ). In this processing step, the connecting element 102 has been separated from the first and second conductors 108, 110. Between the guide or clamping part 140 and 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.

Figure 17 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 ). In this detail it can be seen how 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.

In the Figures 2 to 15 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.

Figure 22 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. In step 301, the flat part 100 according to the invention is first provided. Then in 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.

In 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.

Depending on the shape requirements of the plug, it is possible to bend only the conductors connected to one side of the connecting element 102 into a step-shaped course and to leave the conductors connected to the other side of the connecting element straight. However, it is also possible to bend the conductors on both sides of the connecting element 102 in a step-shaped course. A lateral offset of the contact pins 112, 114 with respect to a plane in which the conductors 108, 110 extend from the connecting element can then be set. A row of contact pins can then lie on one side of the plane, or both rows of contact pins can lie on the same side of the plane. The optional additional bending processes of the conductors connected on the other side of the connecting element 102 are shown in the figure as steps 302a, 304a with a dashed border.

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 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.

In step 306, 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.

In step 308, the folded flat part 100 is encapsulated with an electrically insulating material.

In step 310, the connecting element 102 is severed and the webs 122, 124 are removed or severed.

In an optional step 312 before the overmolding, 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. As a result, 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.

In a final, optional step 314, 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.

In Figure 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.

In a first variant of the method, 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 .

In a second variant of the method, 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. In step 406 the carrier is then detached from the flat part formed by the applied electrically conductive material.

In 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.

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.

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. In the bifilar coil 12, 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.

In both of the devices for power transmission shown in the figures, 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. <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 Auxiliary line 130 third page 132 Offset section

Claims (12)

Electrically conductive, one-piece flat part (100) for a plug (200) with first and second contact pins (112, 114) arranged in two parallel rows and a connection area for a cable, the conductors of which lie next to one another in one plane, comprising a connecting element (102) with a second side (106) opposite a first side (104), with conductors (108, 110) opening into the first and second contact pins (112, 114) extending from the first and from the second side of the connecting element , wherein the conductors (108, 110) lying on the opposite sides of the connecting element (102) are connected to the connecting element (102) offset from one another in such a way that the imaginary straight extension of a conductor (108, 110) on one side of the connecting element (102 ) runs alongside one or between two conductors (108, 110) on the opposite side of the connecting element (102), the first contact pins (112) with the si ch are connected from the first side of the connecting element (102) extending first conductors (108) via an offset region (132) which compensates for the offset of the first and second conductors (108, 110) on the connecting element (102). Flat part (100) according to Claim 1, two adjacent contact pins (112, 114) connected to the same side of the connecting element (102) being connected to one another at a distance from their ends by webs (122, 124). Flat part (100) according to claim 1 or 2, wherein the contact pins (112) connected to the first side (104) of the connecting element (102) are each at first distances (116a-116e) from the connecting element (102) at a first angle to the Run in the direction from which the conductors (108) connected to them extend from the connecting element (102), and the contact pins (114) connected to the second side (106) of the connecting element (102) each at second distances (118a-118e) from the connecting element (102) extend at a second angle to the direction from which the conductors (110) connected to them extend from the connecting element (102), the first and the second angle being mirrored on a folding axis (120) which is transverse to a direction runs in which the first and second conductors (108, 110) extend from the connecting element. Flat part (100) according to claim 3, wherein the contact pins (112) connected to the first side (104) of the connecting element (102) are at a greater distance from a third side (130) connecting the first and second sides (104, 106) ) of the connecting element end as the contact pins (114) connected to the second side (106) of the connecting element (102). Method (400) for producing a flat part (100) according to one of Claims 1 - 4, comprising: - Providing (402a) a plate or sheet metal made of an electrically conductive material (metal, alloy, plastic), and - punching (404a) the flat part,
or - providing (402b) a flat carrier, - applying (404b) an electrically conductive material in the form of the flat part in one or more layers on the carrier, and - Detaching (406) the carrier from the flat part formed by the electrically conductive material. Method (300) for producing a two-row plug (200) with a connection area for a cable, the conductors of which lie next to one another in one plane, using a flat part (100) according to one of Claims 1 to 4, comprising: - Providing (301) the flat part (100) according to one of claims 1 to 4, wherein the method comprises in a first variant: - first bending (302) of the first conductors (108) connected to the first side (104) of the connecting element (102) in a first direction pointing out of the plane of the flat part (100), - Second bending (304) of the first conductor (108) connected to the first side (104) of the connecting element (102) in a direction opposite to the first bending direction, so that first contact pins (112) of the first conductor (108) in a parallel to the plane of the flat part (100) facing the second direction, wherein the method comprises in a second variant: - first bending (302) of the first conductors (108) connected to the first side (104) of the connecting element (102) in a first direction pointing out of the plane of the flat part (100), - first bending (302a) of the second conductors (110) connected to the second side (106) of the connecting element (102) in a second direction pointing out of the plane of the flat part (100), the second direction being opposite to the first direction, each of the method variants also comprising: - folding (306) the connecting element (102) along a folding axis (120) which is transverse to the direction in which the first and second conductors extend from the connecting element, so that they extend from the first side (104) of the Connecting element (102) extending first conductor (108) next to or between the second conductors (110) extending from the second side (106) of the connecting element (102) lie in one plane without touching one another, - Injection molding (308) of the folded flat part (100) with an electrically insulating material, - Separating (310) the connecting element (102) and removing or severing the webs (122, 124) connecting two adjacent contact pins. The method (300) according to claim 6 in the first variant, wherein the second conductors (110) connected to the second side (106) of the connecting element (102) are subjected to two bending processes (302a, 304a), which are the first and the second bending process ( 302, 304) to which the first conductors (108) of the connecting element (102) connected to the first side (104) have been subjected. The method (300) according to claim 6 or 7, wherein, before the overmolding (308) of the folded flat part (100), one or more bends (312) take place in a region of the folded flat part (100) in which those with the first and second Side (104, 106) of the connecting element (102) connected conductors (108, 110) lie in one plane. The method (300) of claim 6, 7 or 8 further comprising: - Separating (314) a part (140) from the body (144) produced by overmolding, the separated part (140) along the conductors (108, 110) separated from the connecting element (102) in a connection area of the plug (200) Is mounted longitudinally displaceable. Two-row plug (200) for a flat ribbon or foil cable, comprising a flat part (100) according to one of Claims 1 to 4 and a body (144) produced by overmolding with an electrically insulating material. Device for power transmission with a ribbon or foil cable and at least one electrically conductively connected two-row plug (200) according to claim 10. Device for power transmission according to claim 11, wherein the ribbon or foil cable is at least partially wound up in a spiral shape.

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