EP4160828A1 - Metallic connector component and method for manufacturing a metallic connector component - Google Patents

Abstract

The invention relates to a metal connector component (1), in particular an electrical contact element or a support sleeve of an electrical connector, having a base body (3) coated with a coating (2) and mechanically formed in a machining section (4). A surface (6, 7) of the coating (2) in the processing section (4) has a defined surface structure (8) at least in sections.

Description

The invention relates to a metallic connector component, in particular an electrical contact element or a support sleeve of an electrical connector, having a base body coated with a coating, according to the preamble of claim 1.

The invention also relates to a method and a device for producing a metal connector component, which has a base body coated with a coating.

An important process in manufacturing technology is forming, in order to bring the underlying workpieces into the desired shape as part of the production of components. The most important manufacturing processes in forming technology are rolling, open-die forging, drop forging, impact extrusion, extrusion, deep drawing and bending. It is therefore a process in which raw parts made of plastic materials such as metals and thermoplastics are brought into a different shape. This is usually done without removing any material from the blanks. The material or workpiece preferably retains its mass and cohesion.

A forming process can be used, among other things, to provide sharp edges of components with a chamfer in order to reduce the risk of injury or to simplify subsequent assembly. A chamfer can advantageously be introduced into the component, for example, by means of an embossing or pressing process.

If the underlying component is a surface-finished component, i.e. a component made from a base body coated with a coating, the forming process can cause the coating to flow. In particular, if the processing section in which the component is formed adjoins an edge or an edge of the component or is arranged close to such an edge, this can result in the coating protruding beyond the edge of the base body after forming. This can have various negative consequences.

The coating protruding over the component can result in sharp edges that pose a risk of injury, and the component can also be of high quality in terms of feel and appearance appear inferior. It can also happen that the overhang of the coating protrudes from the component as chips ("tinsel"), which is particularly problematic when using the component as a component of an electrical connector, since the protruding chips can cause short circuits, for example. If necessary, the overhang can also become completely detached from the component, which can then have a negative effect on the technical cleanliness within the scope of a manufacturing process.

Thus, post-processing steps are often required after the forming of surface-finished or coated components if a component is to be manufactured with high precision. These additional processing steps are to be avoided in particular in the context of machine mass production, since they make production more expensive and prolong the processing time.

High demands are placed on components for electrical and optical connectors in particular. Metallic connector components must therefore be manufactured with high precision and quality. In addition, a particularly economical production process and, in particular, a short process time are also often required for the production of plug connectors, in particular to enable mass production.

In view of the known state of the art, the object of the present invention is to provide a metallic connector component which is mechanically formed in a coated machining section and which can preferably be mass-produced precisely and inexpensively.

The present invention is also based on the object of providing a method by means of which a metal connector component, which is mechanically formed in a coated processing section, can be produced preferably precisely and cost-effectively within the framework of mass production.

In addition, the object of the invention is to provide a device by means of which a metal connector component, which is mechanically formed in a coated processing section, can be produced preferably precisely and cost-effectively within the framework of mass production.

The object is achieved for the metal connector component with the features listed in claim 1. The object is achieved by the features of claim 12 with regard to the method and by claim 15 with regard to the device.

The dependent claims and the features described below relate to advantageous embodiments and variants of the invention.

A metallic connector component is provided which has a base body coated with a coating.

In the context of the invention, a "connector component" can be an intermediate product for further processing, an (intermediate) product for use or assembly in a complex assembly of the connector or an individual component of the connector. The connector component can, among other things, be a component that has not yet been formed into a sleeve-shaped body or only partially formed (e.g. a substantially sheet-metal body) that is further processed in a subsequent production step, in particular stamped or formed or bent. becomes.

The metallic connector component can be used as an independent component in the connector or as a component of a technical complex or assembly in the connector.

The metal connector component is preferably designed as a contact part of a mechanical connector, an electrical connector or an optical connector. The metal connector component can be designed, for example, as an electrical contact element (e.g. inner conductor contact element or outer conductor contact element) or as part of an electrical contact element of an electrical connector. The metal connector component can also be designed, for example, as a support sleeve, housing component or other component of an electrical connector.

The metallic connector component can be designed in one piece or in multiple parts.

The base body of the metal connector component can be coated with the coating all the way around, or only on individual sides (in particular on opposite sides) or only on a single side with the coating. One or more sides of the base body can also be coated only in sections or partially. The coating preferably runs completely on at least one side of the base body.

A coating within the meaning of the invention can be a thin layer or several layers connected to one another, which can be Coating process are applied to the base body (for example, chemically, mechanically and / or thermally). The coating is preferably connected to the base body in a material-to-material and/or form-fitting manner. In particular, it can be provided that the coating is inseparably connected to the base body in such a way that the coating cannot be removed from the base body without being destroyed.

The layer thickness of the coating is preferably smaller than the thickness of the underlying base body, preferably at least a factor of 2 smaller than the thickness of the base body, particularly preferably at least a factor of 10 smaller than the thickness of the base body. The layer thickness of the coating is preferably from 0.1 μm to 10 μm, particularly preferably from 0.5 μm to 5 μm.

The coating preferably serves to influence physical, electrical and/or chemical properties of the finished connector component, which would not emerge from the uncoated base bodies. For example, a coating on a metallic connector component to be used for a connector can serve to reduce the electrical contact resistance and/or to define mechanical insertion forces in a targeted manner through the frictional resistance of the coating. The coating can also refine the connector component in particular in such a way that oxidation, mechanical damage and/or aging of the base body is avoided.

According to the invention, the connector component or the base body is formed mechanically or plastically in a machining section.

In the machining section, the base body preferably has the coating at least in sections, preferably completely.

In principle, the connector component or the base body can be shaped as desired in the processing section. For example, a projection such as a rib, a (partially) annular elevation, a flange or a bulge/bulge, a web or another bending point can be formed in the processing section, or a transition section between two sections, each with different radii, an embossing , but in particular a border or an edge with a chamfer or a transition radius ("form edge").

According to the invention, it is provided that a surface of the coating in the processing section has a defined surface structure, at least in sections.

A "defined surface structure" is understood to mean a surface structure that has been applied or introduced on or in the respective surface through conscious or targeted processing - in contrast to an undefined surface structure as an expression of the roughness of the surface or caused by previous processing errors, tolerances and/or surface imperfections.

The inventor surprisingly found that a defined surface structure can prevent or at least reduce the flow of the coating in the processing section during the mechanical forming. The coating can thus have a textured surface in order to avoid the disadvantages known from the prior art due to the coating flowing during forming.

It has been shown that due to the surface structure during the forming, the coating material can be distributed more advantageously in the processing section, for example by the coating material being able to be distributed in individual “coating valleys” or recesses in the surface. Furthermore, the surface structure can increase the friction with a forming tool and/or with the base body and, in the best case, a form fit with an embossing surface of a forming tool and/or a base body surface or surface of the base body can be produced.

The defined surface structure introduced in the machining section thus leads to a metal connector component which is machined as part of a forming process and which can be produced with high precision and also cost-effectively as part of mass production.

In an advantageous development of the invention, it can be provided that the coating in the technical area of influence of an edge (typically an outer edge of the connector component or the base body, but possibly also an inner edge), a projection, a transition section between two sections, each with different radii (e.g. a step or a shoulder with conical, convex, concave or other radii), a shaped edge, a bending point, a radius transition, a flange, a bulge, a web, a rounding, a chamfer and/or a transition radius , so that a measurable technical effect is achieved by the coating according to the invention. In particular, the coating can run adjacent or adjacent, in particular directly adjacent, to the edge, the projection, the shaped edge, the bending point and/or the transition radius.

The coating can extend, for example, along the edge, the projection, the shaped edge, the bending point or the transition radius.

A "formed edge" can be a defined formed edge or a defined formed edge of the connector component, in particular a formed edge formed at one end or a recess of the connector component, for example an edge provided with a chamfer or a rounded edge, as described below.

A "bend" can be any convex or concave radius transition, such as a step or depression.

A "blend radius" can be any smooth or uneven transition from a first surface of the connector component to a second surface angled to the first surface.

A projection can in particular be a rib (e.g. a rib running in the longitudinal direction of the connector component or in the axial direction), an annular elevation, a partial annular elevation (within an angular segment), a flange, a web or a "punctiform" elevation (Like a bulge or bulge, comparable to a dent).

A recess may also be provided, typically on the surface opposite a projection.

A transition section between two sections, each with a different radius, can be a step or a shoulder, for example, as already mentioned. The transition section can run or be aligned in the circumferential direction and/or in the axial direction.

In an advantageous development of the invention, it can be provided that the base body is designed in the form of a plate. The width and length of the main body, which define the main surfaces of the main body, are preferably very much greater than the thickness of the main body.

The base body can in particular be a one-piece body made from a single material. However, the base body can optionally also be in several parts and therefore have several materials that are mechanically connected to one another.

The base body can preferably be made of a metal (in particular a noble metal), but other materials can also be used within the scope of the invention, such as plastic, glass or ceramics. The base body can preferably be made of copper or of a copper alloy such as brass.

In particular, it can be provided that the base body is designed as sheet metal or in the form of sheet metal.

The base body or the metal connector component can preferably be a stamped and bent part that was produced as part of a stamping and bending process.

According to a development of the invention, it can be provided that the coating has a lower compressive strength than the base body.

"Compressive strength" refers to the resistance of a material to the effects of compressive forces. The compressive strength is the quotient of the breaking load and the cross-sectional area of a body (force per area in N/mm ² ).

In particular, if the coating has a lower compressive strength than the base body, an undesired flow of the coating material on the base body can occur during a forming process. The invention is therefore particularly advantageous for use with coating materials with only a low compressive strength.

According to a development of the invention, it can be provided that the coating is an electrically conductive coating, in particular a metallic coating. In principle, however, other materials can also be used as a coating within the scope of the invention, such as a plastic.

The coating can preferably be a tin coating. However, basically all possible coating materials can be used, including gold, silver, palladium, nickel and copper.

In a further development of the invention it can be provided that the base body is coated on at least two of its sides with the coating, in particular on two sides facing away from or opposite one another, in particular on the two main surfaces of a plate or sheet-like base body. The coating can then preferably be provided (at least partially) with a respective surface structure on each of these sides.

However, it can also be provided that the base body is only coated with the coating on one side, or that more than two sides of the base body are coated (for example all sides of the base body). Each of the sides is then preferably at least partially provided with a respective surface structure, at least in the region of the processing section.

In a development of the invention, it can be provided that the processing section is formed into at least one chamfer formed on an edge or a rim of the metal connector component or that the processing section forms or has a chamfer.

In the context of the present description, a “chamfer” is understood to mean any bevelling, rounding or gradation of an edge.

The width of the chamfer is preferably at least one third of the thickness of the base body, preferably at least half the thickness of the base body.

It can be provided that the bevel has a bevel angle of 10° to 80°, preferably of 15° to 60°.

As already mentioned above, forming processes can be used particularly advantageously for introducing chamfers. The problem of a coating flowing is generally particularly pronounced in the area of the edges or edges of the base body or connector component, which is why the invention can be particularly advantageous for such an application in order to overcome the disadvantages of the prior art.

In a development of the invention, it can be provided that the surface of the coating that has the surface structure is an outer surface of the coating that faces away from the base body.

In this way, a form-fitting connection can be produced with a complementary counter-structure or negative mold of an embossing surface of a forming tool. The surface structure can advantageously be introduced at least into the outer surface of the coating, preferably even through the forming tool itself, in particular Coating through to the corresponding base body surface of the base body and also into the base body, as will be described below.

In a particularly advantageous development of the invention, it can be provided that the surface of the coating that has the surface structure is an inner surface of the coating that faces the base body or is directly connected to the corresponding base body surface of the base body.

The base body preferably has a complementary surface structure (in the context of the invention, the surface structure of the base body can also be referred to as "complementary surface structure" for better distinguishability from the surface structure of the surface of the coating) in order to form a positive connection with that formed on the inner surface of the coating create surface structure.

A positive fit or at least increased friction between the base body and the coating has proven to be particularly suitable for preventing the coating from flowing during the forming process.

In principle, preparations for a corresponding form fit can already be made during the production of the metallic connector component and before the same is formed, for example by first providing the base body surface of the base body to be coated with the complementary surface structure, after which the base body can be coated in such a way that the coating material penetrates into the surface structure of the base body during the coating process, so that finally the surface structure also develops on the inner surface of the coating. However, this process is comparatively complex.

It can be significantly more advantageous to introduce the surface structure into the inner surface of the coating and into the base body surface of the base body at the same time as part of the forming process, by providing the outer surface of the coating with the surface structure in such a way that the surface structure extends through the coating, starting from the outer surface pressed through to the inner surface of the coating, and preferably also produces the corresponding surface structure on the surface of the base body connected to the inner surface of the coating. In this way, a form fit on both sides can be provided, on the one hand between the coating and the base body and on the other hand between the coating and the forming tool, which can prevent the coating from flowing during the forming in a particularly good manner.

As explained above, it can be provided that the surface structure is only partially arranged in the processing section. However, the surface structure can also be provided completely in the processing section, possibly even beyond the processing section.

For example, it can also be provided that the surface structure is spaced from an edge or from the edge of the processing section, for example by at least one layer thickness of the coating or the roughness depth of the surface structure is spaced from the edge. In this way it is possible to prevent the coating material from being pushed over the edge in individual cases as a result of the surface structure being introduced into the coating. As a rule, however, it is not absolutely necessary for the surface structure to be spaced apart from an edge or from the edge of the processing section.

In an advantageous development of the invention, it can be provided that the surface structure is an ordered structure.

The surface structure can form an essentially homogeneous pattern. In particular, the surface structure can form a structure that is periodic at least in sections. Structures of this type can be produced easily and can have reproducible properties. The periodic structure can form, for example, a line pattern, a dot pattern, a honeycomb pattern, a cross pattern or the like. The periodic structure can, for example, have a period length of 0.5 to 300 μm, preferably 0.1 to 100 μm, in at least one spatial direction.

In principle, any desired surface structure can be provided, but a cross-knurl structure has proven to be particularly advantageous. However, another ordered structure (for example a dotted structure, a line structure, a circular structure, a wavy structure, etc.) can also be suitable in order to prevent the coating from flowing or from moving transversely during the forming process.

Alternatively, an unordered structure can also be provided (similar to the surface of sandpaper). Any isotropic or anisotropic surface can be provided.

Macroscopic surface structures such as grooves, webs, pins can also be provided.

The surface structure preferably has indentations ("valleys") and/or elevations ("mountains") on the surface. Preferably, the depressions and elevations alternate in a regular or irregular pattern on the surface.

The difference in height between an elevation and a depression can be, for example, 0.1 μm to 50 μm, preferably 1 μm to 20 μm, particularly preferably 5 μm to 10 μm. The indentations are preferably made in the outer surface of the coating with such a depth that the coating material is pressed into the base body on the opposite side or with the inner surface.

The distance between two indentations separated by an elevation or between two elevations separated by an indentation can be, for example, 1 μm to 200 μm, particularly preferably 10 μm to 100 μm, for example 50 μm to 70 μm.

In an advantageous development of the invention, it can be provided that the peak-to-valley height (so-called “RZ value”) of the surface structure corresponds to at least half the layer thickness of the coating.

In this way, a particularly strong adhesion or lateral fixation of the coating on the base body can be made possible, which is usually already sufficient. In principle, however, the roughness depth of the surface structure can also be greater than half the layer thickness of the coating or smaller than half the layer thickness of the coating.

1. a) Bearbeiten einer Grundkörperfläche des Grundkörpers und/oder einer von dem Grundkörper abgewandten Außenfläche der Beschichtung zur Erzeugung einer definierten Oberflächenstruktur; und
2. b) Druckumformen des mit der Beschichtung beschichteten Grundkörpers in einem die Oberflächenstruktur zumindest abschnittsweise aufweisenden Bearbeitungsabschnitt mittels wenigstens eines Umformwerkzeuges.

The invention also relates to a method for producing a metal connector component, which has a base body coated with a coating, with at least the following method steps:

1. a) processing a base body surface of the base body and/or an outer surface of the coating facing away from the base body to produce a defined surface structure; and
2. b) Pressure forming of the base body coated with the coating in a processing section that has the surface structure at least in sections by means of at least one forming tool.

By processing the base body surface of the base body and/or the outer surface of the coating to produce the defined surface structure, the flow of the coating can be avoided or at least largely avoided, as a result of which metallic connector components can be produced with greater precision than before and in particular without complex post-processing process steps. To the subsequent Removal of tinsel or chips, e.g. B. by air pressure treatment, brushing or other cleaning techniques can be omitted and the process time can therefore be saved. Last but not least, the proposed method can improve the technical cleanliness in the production of corresponding connector components.

By texturing or structuring the surface, in particular if, as described below, the embossing surface of an embossing stamp is provided with a corresponding counter-contour, the coated surface of the connector component can be prevented from being pushed together or rolled up over a large area, thus preventing the formation of chips. Due to the texturing of the surface or the defined surface structure, the pressure on the connector component can be segmented during the forming and the coating can be held securely on the base body or not shifted over a large area.

The process steps of processing the base body surface and/or the outer surface of the coating and the pressure forming can preferably be carried out simultaneously/synchronously, but if necessary also one after the other or sequentially.

The defined surface structure is preferably designed in such a way that the structuring affects the intended functionality of the surface (for example conductivity, etc.) as little as possible.

A surface-structured embossing process for metal connector components with a pre-finished surface can thus be provided in an advantageous manner, in particular for embossing chamfers on stamped parts.

In principle, the invention can be used with any pressure forming process, in particular a rolling process (forming between two or more rotating rollers) or a drop forging process (forming between two or more dies that contain the shape to be produced at least partially as a negative). Freeforming, indenting or pressing through can also be provided as a pressure forming process, for example.

In a particularly preferred development of the invention, it can be provided that the forming tool has embossing stamps (also known as "contour stamps" or "contour forming").

Preferably, the embossing surface of the embossing die facing the connector component has a negative form or counter-structure of the surface structure in order to Simultaneously emboss surface structure with the pressure forming at least in the outer surface of the coating.

The forming tool can thus advantageously be used at the same time as a processing tool for introducing the surface structure and for forming, which can further reduce the process time in the manufacture of the connector component.

The surface structure is preferably also embossed at least partially through the coating into the base body surface of the base body or into the base body.

Provision can be made for the base body to be coated with the coating only as part of the proposed method. Corresponding coating techniques are known, which is why further details are not discussed in more detail. However, within the scope of the claimed method, the base body can also already be coated.

In the context of the proposed method, in a less preferred but nevertheless claimed variant, it can be provided that the base body surface of the base body is first provided with the surface structure or the complementary surface structure by any technique, for example by means of an embossing technique, a subtractive technique or an additive technique layering technique. It can then be provided to coat the base body with the coating in such a way that the coating material is distributed in the elevations and/or depressions of the surface structure of the base body and thereby creates a form fit with the base body.

As part of the proposed method, provision can therefore optionally be made for the forming tool to be initially provided or even produced.

As part of the method, it can be provided that the processing section is adjacent to an edge or a rim of the base body. The base body can be shaped in such a way that a chamfer is formed on the edge or on the edge.

Provision can be made for the base body to be provided with the surface structure on at least two sides facing away from one another.

Provision can be made for the connector component to be formed into a component of the connector, in particular an electrical connector, for example into an electrical contact element or into a support sleeve, only as part of the proposed method.

1. a) einem Bearbeitungswerkzeug das ausgebildet ist, in einer Grundkörperfläche des Grundkörpers und/oder in einer von dem Grundkörper abgewandten Außenfläche der Beschichtung eine definierte Oberflächenstruktur zu erzeugen; und
2. b) wenigstens einem Umformwerkzeug zum Druckumformen des mit der Beschichtung beschichteten Grundkörpers in einem die Oberflächenstruktur zumindest abschnittsweise aufweisenden Bearbeitungsabschnitt.

The invention also relates to a device for producing a metal connector component, which has a base body coated with a coating

1. a) a processing tool which is designed to produce a defined surface structure in a base body surface of the base body and/or in an outer surface of the coating facing away from the base body; and
2. b) at least one forming tool for pressure forming of the base body coated with the coating in a processing section having the surface structure at least in sections.

The machining tool and the forming tool can be tools that are independent of one another. However, the machining tool and the forming tool can also be the same tool, with a negative form of the surface structure being able to be formed on an embossing surface of the forming tool, for example, in order to emboss the surface structure into the coating at the same time as the forming.

The invention also relates to an electrical connector, wherein at least one component of the connector, in particular an electrical contact element or a support sleeve, is designed as a metallic connector component in accordance with the statements above and below.

Features that have been described in connection with one of the objects of the invention, namely given by the metallic connector component according to the invention, the method according to the invention, the device according to the invention or the electrical connector, can also be advantageously implemented for the other objects of the invention. Likewise, advantages that were mentioned in connection with one of the objects of the invention can also be understood in relation to the other objects of the invention.

In addition, it should be pointed out that terms such as "comprising", "having" or "with" do not exclude any other features or steps. Furthermore, terms such as "a" or "that" which indicate a singular number of steps or features do not exclude a plurality of features or steps - and vice versa.

In a puristic embodiment of the invention, however, it can also be provided that the features introduced in the invention with the terms “comprising”, “having” or “with” are listed exhaustively. Accordingly, one or more lists of features can be considered complete within the scope of the invention, example considered for each claim. The invention can consist exclusively of the features mentioned in claim 1, for example.

Furthermore, it should be emphasized that the values and parameters described here are deviations or fluctuations of ±10% or less, preferably ±5% or less, more preferably ±1% or less, and very particularly preferably ±0.1% or less of the respectively named Include value or parameter, provided that these deviations are not excluded in the implementation of the invention in practice. The specification of ranges by means of initial and final values also includes all those values and fractions that are enclosed by the range specified in each case, in particular the initial and final values and a respective mean value.

Exemplary embodiments of the invention are described in more detail below with reference to the drawings.

The figures each show preferred exemplary embodiments in which individual features of the present invention are shown in combination with one another. Features of an exemplary embodiment can also be implemented separately from the other features of the same exemplary embodiment and can accordingly easily be combined with features of other exemplary embodiments by a person skilled in the art to form further meaningful combinations and sub-combinations.

Elements with the same function are provided with the same reference symbols in the figures.

Figur 1

eine metallische Steckverbinderkomponente gemäß einem ersten Ausführungsbeispiel der Erfindung in einer perspektivischen Darstellung;

Figur 2

eine metallische Steckverbinderkomponente gemäß einem zweiten Ausführungsbeispiel der Erfindung in einer perspektivischen Darstellung;

Figur 3

eine metallische Steckverbinderkomponente gemäß einem dritten Ausführungsbeispiel der Erfindung in einer perspektivischen Darstellung;

Figur 4

eine metallische Steckverbinderkomponente gemäß einem dritten Ausführungsbeispiel der Erfindung in einer perspektivischen Darstellung;

Figur 5

eine metallische Steckverbinderkomponente gemäß einem vierten Ausführungsbeispiel der Erfindung in einer perspektivischen Darstellung;

Figur 6

eine beispielhafte, im Rahmen der Erfindung verwendbare Oberflächenstruktur (Kreuzrändelstruktur);

Figur 7

eine weitere im Rahmen der Erfindung verwendbare Oberflächenstruktur (Linienstruktur);

Figur 8

eine weitere im Rahmen der Erfindung verwendbare Oberflächenstruktur (Punktierung);

Figur 9

die in einem weiteren Verarbeitungsschritt zu einem hülsenförmigen Körper umgeformte, metallische Steckverbinderkomponente der Figur 1 in einer perspektivischen Schnittdarstellung;

Figur 10

eine weitere hülsenförmige, metallische Steckverbinderkomponente gemäß einem Ausführungsbeispiel der Erfindung in einer perspektivischen Schnittdarstellung;

Figur 11

eine Vorrichtung zur Herstellung einer metallischen Steckverbinderkomponente mit einem geöffneten Umformwerkzeug gemäß einem Ausführungsbeispiel der Erfindung, vor dem Umformen der Steckverbinderkomponente;

Figur 12

die Vorrichtung der Figur 11 in einem geschlossenen Zustand des Umformwerkzeugs, nach dem Umformen der Steckverbinderkomponente; und

Figur 13

eine Vorrichtung zur Herstellung einer metallischen Steckverbinderkomponente, mit einem Umformwerkzeug gemäß dem Stand der Technik.

They show schematically:

figure 1

a metallic connector component according to a first embodiment of the invention in a perspective view;

figure 2

a metallic connector component according to a second embodiment of the invention in a perspective view;

figure 3

a metallic connector component according to a third embodiment of the invention in a perspective view;

figure 4

a metallic connector component according to a third embodiment of the invention in a perspective view;

figure 5

a metallic connector component according to a fourth embodiment of the invention in a perspective view;

figure 6

an exemplary surface structure (cross-knurl structure) that can be used within the scope of the invention;

figure 7

another surface structure (line structure) that can be used within the scope of the invention;

figure 8

another surface structure that can be used within the scope of the invention (stippling);

figure 9

the metal connector component, which is formed into a sleeve-shaped body in a further processing step figure 1 in a perspective sectional view;

figure 10

another sleeve-shaped, metallic connector component according to an embodiment of the invention in a perspective sectional view;

figure 11

an apparatus for manufacturing a metal connector component with an open forming tool according to an embodiment of the invention, before forming the connector component;

figure 12

the device of figure 11 in a closed state of the forming tool, after forming the connector component; and

figure 13

a device for producing a metal connector component, with a forming tool according to the prior art.

figure 1 shows a perspective view of a metallic connector component 1 according to the invention according to a first embodiment. The connector component 1 shown can be formed, for example, as part of the manufacturing process into an electrical contact element or into a support sleeve of an electrical connector, whereby the in figure 9 illustrated, sleeve-shaped body can result.

The connector component 1 has a base body 3 which is coated with a coating 2 and is in the form of a plate, preferably made of a metal. In which The base body 3 can in particular be sheet metal made from a noble metal, and the coating 2 can be a metallic coating, such as a tin coating. In the exemplary embodiments, a base body 3 coated on both sides is shown as an example, but this is not to be understood as limiting. In principle, only a single side of the base body 3 or more than two sides of the base body 3 can also be correspondingly coated.

The metal connector component 1 or the base body 3 is mechanically formed in a processing section 4 . The processing section 4 can be shaped as desired. However, the advantages of the invention unfold in particular when the processing section 4 is formed into at least one shaped edge or chamfer 5 formed on an edge or an edge R of the connector component 1 or has a chamfer 5, as shown, or in the processing section 4 has at least one projection 5' (cf. FIG. 10) and/or a transition radius. Preferably, the coating 2 is adjacent to the edge R, to the protrusion 5' and/or to the transition radius, as shown. However, the coating 2 can also be at a distance from the edge R or from the bevel 5, the projection 5' or the transition radius.

The width b of the bevel 5 can preferably be greater than half the thickness d of the base body 3. The bevel angle α of the bevel 5 can be between 10° and 80°, preferably between 15° and 60°. The layer thickness s of the coating 2 can be about 1 μm, for example.

In particular, if the coating 2 has a lower compressive strength than the base body 3, the forming process can lead to an unfavorable flow of the coating 2 on the base body 3, as a result of which the coating 2 can protrude beyond the edge R of the base body 3 (see illustration of the prior art according to Figure 13) or detaches itself at least partially from the base body 3 in some other way (in the case of the in figure 10 shown projection 5 'usually in the radial direction). Insofar as a high-precision metal connector component 1 is to be produced, post-processing is unavoidable in the previously known prior art. The present invention is intended to remedy this.

It is proposed within the scope of the invention that a surface 6 , 7 of the coating 2 has a defined surface structure 8 in the processing section 4 . A chip protruding from the metal connector component 1 can be prevented in the proposed manner. It can thus be highly precise, formed and produce coated metallic connector components 1 without complex post-processing.

In figure 1 For example, only the upper coating 2, on which the bevel 5 is formed, has the defined surface structure 8. The lower coating 2 is unprocessed (see enlarged sectional view). However, all coatings 2, in particular in the processing section 4, preferably have a corresponding surface structure 8, as in FIGS Figures 11 and 12 implied.

The surface of the coating 2, which has the surface structure 8, can in particular be an outer surface 6 of the coating 2 facing away from the base body 3, as a result of which a positive connection can be produced with a complementary negative mold 9 of an embossing surface 10 of a forming tool 11 (cf. Figures 11 and 12 ).

The surface of the coating 2 which has the surface structure 8 can also be an inner surface 7 of the coating 2 facing the base body 3 . Finally, the base body 3 can have a complementary surface structure 8' (cf. enlarged sectional view in figure 1 ) in order to create a positive connection with the surface structure 8 of the coating 2.

Corresponding surface structures 8 on the outer surface 6 and/or the inner surface 7 of the coating 2 and on the base body 3 can be produced simultaneously with the forming process, as will be described below.

Provision can be made for the surface structure 8, 8' to be arranged entirely in the processing section 4, as shown in FIG figure 1 implied. In principle, however, only a sectional arrangement of the surface structure 8, 8' can be provided in the processing section 4 (cf. figure 2 ), a division of the surface structure 8, 8' over several areas of the processing section 4 (cf. figure 3 ), a surface structure 8, 8', which goes beyond the processing section 4 (cf. figure 4 ) or also a surface structure 8, 8', which extends over the entire connector component 1 (cf. figure 5 ).

An ordered surface structure 8, 8' is preferably provided, which has elevations 12 and depressions 13 (cf. in particular the enlarged sectional view in figure 1 ). The peak-to-valley height of the surface structure 8, 8' can preferably correspond to at least half the layer thickness s of the coating 2.

A cross knurled structure has proven to be a particularly suitable surface structure 8, 8', as shown in figure 6 implied. In principle, however, any desired surface structures 8, 8' can be provided in order to prevent the coating 2 from flowing on the base body 3, for example a line structure (cf. figure 7 ) or puncturing through individual elevations 12 and/or depressions 13 (cf. figure 8 ). A disordered surface structure 8, 8' can also be provided.

As already mentioned, the metal connector component 1 can also be just an intermediate product that is formed into a sleeve-shaped body, for example, in a further production step. Two examples of a sleeve-shaped metal connector component 1 are in the Figures 9 and 10 shown - an initially flat connector component 1 can be bent accordingly. The connector component 1 can also be further processed in some other way, for example punched out of a larger flat body and/or provided with punched-out portions.

In addition to the introduction of chamfers 5 in the area of edges R or edges, the invention can also be particularly advantageous for connector components 1 that have projections 5', bending points or transition radii, for example in the form of a (preferably, but not necessarily, annularly circumferential ) bulge 5', a flange or bulge, as in figure 10 shown. Structures of this type are known, for example, in the case of outer conductor contact elements of FAKRA connectors. The invention can also be advantageously used for use with a rib formed on (or in) the connector component 1, for example a rib extending in the longitudinal direction of the connector component 1 (not shown in the figures).

A suitable method and an apparatus 14 for producing the connector component 1 are based on the Figures 11 and 12 are described below.

As part of the proposed method, it is provided that a base body surface 15 of the base body 3 and/or an outer surface 6 of the coating 2 facing away from the base body 3 are processed in order to produce the defined surface structure 8, 8′.

Furthermore, it is provided that the base body 3 coated with the coating 2 is formed within the scope of a pressure forming process in a processing section 4 having the surface structure 8, 8' by means of at least one forming tool 11. In the exemplary embodiment, the forming tool 11 for pressure forming and the processing tool 16 for introducing the surface structure 8, 8' are embossing dies 17, which can be used simultaneously for reshaping the connector component 1 and for introducing the surface structure 8, 8'. The embossing surfaces 10 of the forming tool 11 or the embossing stamp 17 can be processed beforehand (not shown) in order to produce a negative form 9 of the surface structure 8, 8'. If the embossing stamps 17 are thus placed on one another during the forming, the negative form 9 of the surface structure 8 is embossed at least into the outer surface 6 of the coating 2 at the same time as the pressure forming. However, embossing is preferably carried out through the coating 2 into the base body surface 15 of the base body 3 in order to create a form fit between the coating 2 and the embossing die 17 on the one hand and a form fit between the coating 2 and the base body 3 on the other.

In contrast to the in figure 13 In the known prior art shown, the coating 2 is reliably prevented from flowing beyond the edge R of the base body 3 .

Claims (15)

Metallic connector component (1), in particular electrical contact element or support sleeve of an electrical connector, having a base body (3) coated with a coating (2) which is mechanically formed in a machining section (4),
characterized in that
a surface (6, 7) of the coating (2) in the processing section (4) has a defined surface structure (8) at least in sections. Metallic connector component (1) according to claim 1,
characterized in that
the coating (2) runs adjacent to an edge (R) and/or a projection (5') and/or a transition section formed between two sections each having different radii. Metallic connector component (1) according to claim 1 or 2,
characterized in that
the base body (3) is made of a metal in the form of a plate, in particular is made of a precious metal in the form of a sheet. Metallic connector component (1) according to any one of claims 1 to 3,
characterized in that
the coating (2) has a lower compressive strength than the base body (3). Metallic connector component (1) according to any one of claims 1 to 4,
characterized in that
the coating (2) is a metallic coating, in particular a tin coating. Metallic connector component (1) according to any one of claims 1 to 5,
characterized in that
the base body (3) is coated with the coating (2) on at least two sides facing away from one another, the coating (2) being provided with the surface structure (8) on the two opposite sides. Metallic connector component (1) according to any one of claims 1 to 6,
characterized in that
the processing section (4) is formed into at least one chamfer (5) formed on an edge (R) of the metal connector component (1). Metallic connector component (1) according to any one of claims 1 to 7,
characterized by that
the surface of the coating (2), which has the surface structure (8), is an outer surface (6) of the coating (2) facing away from the base body (3), the surface structure (8) being designed to form a positive connection with a to produce a complementary negative mold (9) of an embossing surface (10) of a forming tool (11). Metallic connector component (1) according to any one of claims 1 to 8,
characterized in that
the surface of the coating (2), which has the surface structure (8), is an inner surface (7) of the coating (2) facing the base body (3), the base body (3) having a complementary surface structure (8') in order to to establish a positive connection with the surface structure (8) of the coating (2). Metallic connector component (1) according to any one of claims 1 to 9,
characterized in that
the surface structure (8) is an ordered structure, preferably a knurled structure. Metallic connector component (1) according to any one of claims 1 to 10,
characterized in that
the peak-to-valley height of the surface structure (8) corresponds to at least half the layer thickness (s) of the coating (2). Method for producing a metal connector component (1), which has a base body (3) coated with a coating (2), with at least the following method steps: a) processing a base body surface (15) of the base body (3) and/or an outer surface (6) of the coating (2) facing away from the base body (3) to produce a defined surface structure (8); and b) Pressure forming of the base body (3) coated with the coating (2) in a processing section (4) having the surface structure (8) at least in sections, using at least one forming tool (11). Method according to claim 12,
characterized in that
the surface structure (8. 8') is embossed at least into the outer surface (6) of the coating (2) at the same time as the pressure forming, preferably embossed through the coating (2) into the base body (3). Method according to claim 12 or 13,
characterized in that
the processing section (4) adjoins an edge (R) of the base body (3), the base body (3) being shaped in such a way that a chamfer (5) is formed on the edge (R). Device (14) for producing a metal connector component (1) which has a base body (3) coated with a coating (2). a) a machining tool (16) which is designed to have a defined surface structure (8, 8 ') to create; and b) at least one forming tool (11) for pressure forming the base body (3) coated with the coating (2) in a processing section (4) having the surface structure (8, 8') at least in sections.

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