FR3077166A1 - ELECTRIC CONNECTOR WITH CONDUCTIVE BLADES AND CORRESPONDING METHOD - Google Patents

Abstract

Electrical connector (1) comprising a male contact (5) and a female contact (10), the male contact being adapted to be inserted into the female contact according to an insertion axis (D), the female contact defining a housing (12) ) for at least partially receiving the male contact in an inserted configuration of the electrical connector, the female contact having an electrically conductive side wall radially delimiting the housing, the side wall comprising successively along the insertion axis a middle part, and a part end (32) through which the male contact enters the housing. The middle portion has a plurality of substantially axial oblong openings (34) defining between them flexible blades (36), the end portion continuously surrounding the male contact about the insertion axis in the inserted configuration. The flexible blades are movable between a position curved radially towards the insertion axis, occupied in a non-inserted configuration of the electrical connector, and a position pressed against the male contact, occupied in the inserted configuration of the electrical connector.

Description

Electrical connector with conductive blades and corresponding method

The present invention relates to an electrical connector comprising a male contact and a female contact, the male contact being adapted to be inserted into the female contact along an insertion axis, the female contact defining a housing for at least partially receiving the male contact in an inserted configuration of the electrical connector, the female contact having an electrically conductive side wall radially delimiting the housing, the side wall successively comprising along the insertion axis a middle part, and an end part through which the male contact enters housing.

The invention also relates to a corresponding electrical connection method.

The electrical connector is suitable for transmitting electrical information of the signal or power type to control it or supply the electrical equipment.

Two categories of these electrical connectors are currently known. A first category includes connectors having an interface intended to guarantee a good contact surface. The interface is usually made using wire or a stamped plate to create the proper shape. This category has the advantage of having low insertion forces and good resistance to vibrations. However, the number of parts used to make the interface is relatively high, and the space occupied by the interface creates space. In addition, this type of connector is relatively expensive.

In the second category, the electrical contact is ensured by the pressure of the two contacts, which must be high, in order to compensate for a small contact surface. These connectors have a lower manufacturing cost, but also high insertion forces and less good resistance to vibrations and fretting, that is to say contact wear which affects the contact surfaces of the contact. male and female contact.

An object of the invention is therefore to provide an electrical connector having a reasonable insertion force, good resistance to vibrations and a small footprint compared to its electrical performance, while remaining simple to manufacture and at a price. competitive.

To this end, the invention relates to an electrical connector of the type described below, in which:

the middle part has a plurality of oblong substantially axial openings defining between them flexible blades, the end part continuously surrounding the male contact around the insertion axis in the inserted configuration, and

- the flexible blades are movable between a curved position, occupied in a non-inserted configuration of the electrical connector and in which the flexible blades are curved radially towards the insertion axis, and a flat position, occupied in the inserted configuration of the connector electric and in which the flexible blades are pressed against the male contact.

According to particular embodiments, the electrical connector comprises one or more of the following characteristics, taken in isolation or in any technically possible combination:

- In the non-inserted configuration, each of the flexible blades has an elliptical profile in section along a radial half-plane;

- in the non-inserted configuration, the housing has an opening diameter and a bottom diameter perpendicular to the insertion axis, the bottom diameter being less than or equal to the opening diameter, and the flexible blades form a necking of the housing having a necking diameter strictly less than the opening diameter and the bottom diameter;

- The male contact has a substantially cylindrical external surface having an external diameter perpendicular to the insertion axis, and the external diameter is strictly between the necking diameter and the opening diameter;

the female contact comprises a first part made of a first electrically conductive material and defining the housing, and a second part fixed to the first part and made of a second electrically conductive material and distinct from the first material, the second part being adapted to be crimped on at least one electric cable, the first material being more elastic than the second material, and the second material being more ductile than the first material;

- The second part defines a crimping housing intended to receive the electric cable, the crimping housing preferably having a passage section greater than or equal to 0.5 mm ² and less than or equal to 2.5 mm ² ;

the male contact comprises a first part made of a third electrically conductive material and configured to be at least partially inserted into the housing, and a second part fixed to the first part and made of a fourth electrically conductive material separate from the third material, the second part being adapted to be crimped onto at least one electric cable, the third material being at least as elastic as the fourth material, and the fourth material being more ductile than the third material;

the third material and the fourth material are identical respectively to the first material and to the second material; and

- each of the male contact and the female contact further comprises at least one clip for fixing an insulating element intended to protect a user from the electrical connector, the clip being an attached piece, or made integrally with the first part.

The subject of the invention is also a method of electrical connection comprising at least the following steps:

- Supply of an electrical connector comprising a male contact and a female contact, the female contact defining a housing for at least partially receiving the male contact along an insertion axis in an inserted configuration of the electrical connector, the female contact having a wall electrically conductive lateral delimiting the housing radially, the lateral wall successively comprising along the insertion axis a middle part, and an end part through which the male contact enters the housing, the middle part having a plurality of oblong openings substantially axial defining between them flexible blades, and the end part continuously surrounding the male contact around the insertion axis in the inserted configuration,

- insertion of the male contact into the female contact to put the electrical connector in the inserted configuration, and

- displacement of the flexible blades from a curved position, occupied in a non-inserted configuration of the electrical connector and in which the flexible blades are curved radially towards the insertion axis, towards a pressed position, occupied in the inserted configuration of the connector electric and in which the flexible blades are pressed against the male contact.

The invention will be better understood on reading the description which follows, given solely by way of example and made with reference to the appended drawings, in which:

FIG. 1 is a perspective view of an electrical connector according to the invention in the non-inserted configuration,

FIG. 2 is an exploded view of the male contact shown in FIG. 1,

FIG. 3 is an exploded view of the female contact shown in FIG. 1,

FIG. 4 is a view in axial section of the connector shown in FIG. 1, the male and female contacts being in the non-inserted configuration,

FIG. 5 is an exploded view of a female contact constituting a first variant of the female contact shown in FIGS. 1, 3 and 4, and

- Figure 6 is an exploded view of a female contact constituting a second variant of the female contact shown in Figures 1,2 and 4.

Referring to Figures 1 to 4, an electrical connector 1 according to the invention is described.

The electrical connector 1 comprises a male contact 5 and a female contact 10. The electrical connector 1 is movable between a non-inserted configuration (shown in FIGS. 1 and 4 in which the male contact 5 is away from the female contact 10 , and an inserted configuration, in which the male contact 10 is at least partially received along an insertion axis D in a housing 12 defined by the female contact.

The inserted configuration is deduced from the non-inserted configuration shown in FIG. 4 by an insertion of the male contact 5 into the female contact 10 along the insertion axis D.

Optionally, the electrical connector 1 also comprises one or more insulating elements (not shown) fixed on the male contact 5 and / or on the female contact 10. This or these insulating elements are obviously adapted so as not to oppose the insertion from male contact 5 to female contact 10.

Advantageously, the female contact 10 comprises a first distal part 14 made of a first electrically conductive material, and a second proximal part 16 fixed on the first part and made of a second electrically conductive material separate from the first material.

By "distal" is meant, for each of the contacts, the side defined by the direction of insertion along the insertion axis D. Correspondingly, by "proximal" is meant the side opposite to the insertion along the axis Insertion D.

The female contact 10 optionally comprises a fixing clip 18 making it possible to fix one of the insulating elements on the female contact.

By “electrically conductive” is meant, for example, that the resistivity of the material is less than or equal to 10 ⁺¹ ° Ω-m.

The resistivity is advantageously measured according to standard EN / IEC 62631-32: 2015 (Dielectric and resistive properties of materials - Part 3-3: Determination of resistive properties (direct current methods)).

The first material is advantageously more elastic than the second material. The elasticity of the first material must be sufficient to allow elastic deformation (not permanent) during use when the flexible blades 36 are pressed against the male contact 5 in the inserted configuration. The first material is for example brass (CuZn39Pb3), aluminum or copper.

The second material is advantageously more ductile than the first material. The ductility of the second material must be sufficient to allow plastic deformation (permanent) without creating cracks during the crimping of the parts 16 on the cable 20. The second material is for example brass (CuZn35Pb2) or copper.

The second part 16 is adapted to be crimped onto at least one electric cable 20. On the proximal side, the second part 16 defines a crimping housing 22 configured to receive the cable 20.

On the distal side, the second part 16 defines a fixing housing 24 in which the first part 14 is for example force-fitted, advantageously along the insertion axis D.

The crimping housing 22 is for example substantially cylindrical and has a passage section S1 at least equal to the section of the largest cable to be crimped, for example 2.5 mm ² .

The second part 14 defines the housing 12. The second part 14 comprises a fixing part 26 adapted to be inserted in the fixing housing 24, and a side wall 28 integral with the fixing part 26 and delimiting the housing radially

12.

By "radial" is meant potentially all the directions defined radially from the insertion axis D.

The side wall 28 comprises, successively along the insertion axis D, a central portion 30 and an end portion 32 through which the male contact 5 enters the housing 12.

The middle part 30 has a plurality of openings 34 (four in number in the example shown) being understood to be substantially axially and defining flexible blades 36 (also four in number in the example shown).

The end part 32 is configured to continuously surround the male contact 5 around the insertion axis D in the inserted configuration.

The end portion 32 is for example substantially annular. The end portion 32 defines an opening diameter AD2 of the housing 12 perpendicular to the insertion axis D.

The housing 12 has a bottom diameter AD3 advantageously less than or equal to the opening diameter AD2.

The flexible blades 36 extend axially from the bottom of the housing 12 to the end portion 32. The flexible blades 36 are curved radially towards the insertion axis D in the non-inserted configuration of the connector 1.

The flexible blades 36 are pressed against the male contact 5 in the inserted configuration.

In the non-inserted configuration, the flexible blades 36 form a neck 38 of the housing 12 having a neck diameter AD1 strictly less than the opening diameter AD2 and the bottom diameter AD3.

Each flexible blade 36 advantageously has an elliptical profile in section along a radial half-plane P. This means that, over at least part of its length along the insertion axis D, each flexible blade 36 forms a portion d 'An ellipse E so that the flexible blade follows the shape of the active part 50 in order to have a sufficient contact surface so as not to increase the contact resistance with a reasonable insertion force. For example, for a diameter of the active part 50 of 1.5 mm ² , the insertion force is less than 2.5 N and the sum of the contact surface of all the flexible blades 36 is at least equal to the section of the active part 50.

The openings 34 advantageously have a certain width around the insertion axis D.

This width is defined so as to allow the flexible blades 36 to deform elastically in order to advantageously match the shape of the active part 50.

According to a variant not shown, the first part 14 and the second part 16 came from one material and therefore consist of the same material.

According to still other variants, the first part 14 and the second part 16 are formed from other materials.

In the example shown, the male contact 5 comprises a first distal part 44 made of a third electrically conductive material and configured for at least partially inserted in the housing 12, and a second proximal part 46 fixed on the first part and produced in a fourth electrically conductive material distinct from the third material.

Optionally, the male contact 5 also includes a clip 48 adapted to fix one of the insulating elements on the male contact.

The third material is advantageously similar to the first material.

The clip 18 has for example a “C” shape and is advantageously adapted to be clipped (snapped) onto a shoulder of the second part 16.

The clip 18 is for example made of stainless steel or any other elastic material having mechanical characteristics close to those of the springs.

The first part 44 is configured to be partially inserted in the housing 12.

The second part 44 comprises a fixing part 49 adapted to be inserted axially by force into the first part 46, and an active part 50 having a substantially cylindrical surface 52.

The active part 50 comprises an axial end 54 opposite the fixing part 49 and configured to reach the bottom of the housing 12.

The surface 52 has an external diameter BD1 perpendicular to the insertion axis D, the external diameter being strictly between the necking diameter AD1 and the opening diameter AD2.

The axial end 54 has for example a conical shape rounded at its top.

The second part 46 is advantageously similar to the second part 16 of the female contact 10.

Thus, the fourth material is therefore advantageously similar to the second material.

The second part 46 therefore comprises a crimping housing 56 similar to the crimping housing 22 and suitable for crimping an electric cable 58, for example similar to the electric cable 20. The ductility of the fourth material is adapted to allow plastic deformation (permanent), without creating cracks, during crimping of the second part 46 on the cable 20.

The clip 48 is advantageously similar to the clip 18 of the female contact 10.

According to a variant not shown, the first part 44 and the second part 46 have come in one piece.

According to another variant, the first part 44 and the second part 46 are made of the same material.

According to yet another variant, the third material and the fourth material are respectively distinct from the first material and from the second material.

To mount the connector 1, the first part 14 of the female contact 10 is forcibly inserted into the second part 16.

The electric cable 20 is introduced into the crimping housing 22 and, using a tool not shown, is pressed on the walls of the crimping housing to crimp the electric cable. Thanks to the clip 18, one of the insulating elements (not shown) is fixed to the female contact 10.

The above mounting operations can be performed in the order shown, or in a different order.

Similarly, to obtain the male contact 5, the first part 44 is forcibly inserted into the second part 46. The electric cable 58 is crimped in the same way in the crimping housing 56.

The clip 48 is then used to fix one of the insulating elements to the male contact 5.

These operations can also be carried out in a different order.

The operation of connector 1 is deduced from its structure and will now be described briefly.

In the non-inserted configuration, the internal faces of the flexible blades 36 of the female contact 10 are electrically connected to the electric cable 20. Likewise, the external surface 52 of the first part 44 of the male contact 5 is electrically connected to the electric cable 58.

The insulating elements (not shown) fixed on the male contact 5 and the male contact 10 allow a user to grasp these contacts and to insert the active part 50 of the male contact 5 into the housing 12 formed by the female contact 10 along the insertion axis D

The axial end 54 of the male contact 5 enters the housing 12 through the end part 32. Then the external surface 52 of the active part 50 comes into mechanical contact with the flexible blades 36.

As the part 50 advances in the housing 12 and approaches, then exceeds the neck 38, the flexible blades 36 deform radially outward.

In other words, the flexible blades 36 pass from an inwardly curved shape which they occupied in the non-inserted configuration, to a substantially non-curved shape which allows them to be pressed against the external surface 52 in the inserted configuration. .

Thus, in the inserted configuration, the electrical contact between the external surface 52 and the flexible blades 36 is very good. The total contact surface is advantageously at least equal to the section of the part 50 according to a plane perpendicular to the insertion axis D. The contact surface is advantageously distributed angularly around the insertion axis D, for example on 360 °. For example, for a diameter of the active part 50 of 1.5 mm, the contact surface of all the flexible blades 36 is at least equal to the section of the active part 50.

Thanks to the characteristics described below, the electrical connector 1 has good resistance to vibration and a small footprint, as well as good electrical performance and a competitive price.

Likewise, the effort to insert the male contact 5 into the male contact 10 remains reasonable. For example, for a diameter of the active part 50 of 1.5 mm, the force is less than 2.5 N.

The effort to remove the male contact 5 is also moderate.

Thanks to the optional feature that the first material is more elastic than the second material, the flexible blades 36 have the flexibility required to ensure very good electrical contact with the active part 50 of the male contact 5 in the inserted configuration.

Thanks to the optional characteristic that the second material is more ductile than the first material, crimping is carried out easily with one or more electric cables such as electric cable 20, these cables being able to have different diameters.

The advantages mentioned above for the female contact 10 are transposed if necessary to the male contact 5.

The characteristics of the female contact 10 guarantee a very good electrical contact of each of the flexible blades 36, that is to say 360 ° around the insertion axis D if we except the width of the openings 34.

The electrical and mechanical performance of connector 1 is equivalent to that of an interface contact, but is obtained for the price of a standard contact without interface.

The female contact 10 being in two pieces if we except the clip 18, it is possible to use the same first part 14 for different sections of the electric cable 20, for example from 0.5 mm ² to 2.5 mm ² . The ductility of the material used for the manufacture of the second part 16 is adapted to allow the plastic (permanent) deformation of the second part, without creating cracks during crimping on the cable 20.

It is also possible to apply different surface treatments to the first part 14 and the second part 16.

This optimizes the number of references and their prices.

With reference to FIG. 5, a female contact 110 is described constituting a first variant of the female contact 10 represented in FIGS. 1, 3 and 4.

The female contact 110 is analogous to the female contact 10. The substantially identical elements have the same reference numbers and will not be described again. Only the differences will be described in detail below.

In the female contact 110, the second part 16 is advantageously a little shorter along the insertion axis D than that of the female contact 10.

The second part 16 has a roughly cylindrical general shape.

The female contact 110 comprises a clip 118 which is more complex than the clip 18.

The clip 118 is adapted to be fixed on the first part 14 around the flexible blades 36.

The clip 118 comprises an envelope 120 in the shape of a "C" in view along the insertion axis D, in which two cutouts advantageously made form two flexible blades 122 which move radially away from the rest of the envelope 120.

With reference to FIG. 6, a female contact 210 is described constituting a second variant of the female contact 10.

The female contact 210 is analogous to the female contact 10 shown in FIGS. 1, 3 and 4. Only the differences will be described below.

The female contact 210 comprises a clip 218 made integrally with the first part 14.

The second part 16 comprises an insertion part 201 adapted to be inserted into a crimping housing 222 of the first part 14.

The clip 218 has for example two ears 224 extending on either side of the insertion axis D.

Depending on the case, the first part 16 of the female contact 10 can be produced by machining a bar (not shown), or else by cutting and stacking a plate or a jail (not shown).

Claims (10)

1Electrical connector (1) comprising a male contact (5) and a female contact (10), the male contact (5) being adapted to be inserted into the female contact (10) along an insertion axis (D), the contact female (10) defining a housing (12) for at least partially receiving the male contact (5) in an inserted configuration of the electrical connector (1), the female contact (10) having an electrically conductive side wall (28) delimiting radially the housing (12), the side wall (28) successively comprising along the insertion axis (D) a middle part (30), and an end part (32) through which the male contact (5) enters the housing (12), characterized in that: - the middle part (30) has a plurality of substantially axial oblong openings (34) defining between them flexible blades (36), the end part (32) continuously surrounding the male contact (5) around the axis insertion (D) in the inserted configuration, and the flexible blades (36) are movable between a curved position, occupied in a non-inserted configuration of the electrical connector (1) and in which the flexible blades (36) are curved radially towards the insertion axis (D), and a flat position, occupied in the inserted configuration of the electrical connector (1) and in which the flexible blades (36) are flat on the male contact (5). 2, -Electrical connector (1) according to claim 1, wherein, in the non-inserted configuration, each of the flexible blades (36) has an elliptical profile in section along a radial half-plane (P). 3. -Electrical connector (1) according to claim 1 or 2, in which, in the non-inserted configuration: - The housing (12) has an opening diameter (AD2) and a bottom diameter (AD3) perpendicular to the insertion axis (D), the bottom diameter (AD3) being less than or equal to the diameter of opening (AD2), and - the flexible blades (36) form a neck (38) of the housing (12) having a neck diameter (AD1) strictly less than the opening diameter (AD2) and the bottom diameter (AD3). 4. - electrical connector (1) according to claim 3, in which: - the male contact (5) has a substantially cylindrical external surface (52) having an external diameter (BD1) perpendicular to the insertion axis (D), and - the external diameter (BD1) is strictly between the necking diameter (AD1) and the opening diameter (AD2). 5. -Electrical connector (1) according to any one of claims 1 to 4, in which the female contact (10) comprises a first part (14) made of a first electrically conductive material and defining the housing (12), and a second part (16) fixed on the first part (14) and made of a second electrically conductive material and distinct from the first material, the second part (16) being adapted to be crimped onto at least one electric cable (20), the the first material being more elastic than the second material, and the second material being more ductile than the first material. 6. -Electrical connector (1) according to claim 5, wherein the second part defines a crimping housing (22) intended to receive the electric cable (20), the crimping housing (22) preferably having a passage section (51) greater than or equal to 0.5 mm ² and less than or equal to 2.5 mm ² . 7. - electrical connector (1) according to claim 5 or 6, wherein the male contact (5) comprises a first part (44) made of a third electrically conductive material and configured to be at least partially inserted in the housing (12 ), and a second part (46) fixed on the first part (44) and made of a fourth electrically conductive material and distinct from the third material, the second part (46) being adapted to be crimped on at least one electric cable (58 ), the third material being at least as elastic as the fourth material, and the fourth material being more ductile than the third material. 8. -Electrical connector (1) according to any one of claims 5 to 7, in which the third material and the fourth material are identical respectively to the first material and to the second material. 9. -Electrical connector (1) according to any one of claims 5 to 8, wherein each of the male contact (5) and the female contact (10) further comprises at least one clip (18, 48) for fixing d 'an insulating element intended to protect a user from the electrical connector (1), the clip (18, 48) being an attached part, or made of material with the first part. 10.- Method of electrical connection comprising at least the following steps: - Supply of an electrical connector (1) comprising a male contact (5) and a female contact (10), the female contact (10) defining a housing (12) for at least partially receiving the male contact (5) according to a insertion axis (D) in an inserted configuration of the electrical connector (1), the female contact (10) having an electrically conductive side wall (28) delimiting the housing (12), the side wall (28) successively comprising according to the insertion axis (D) a middle part (30), and an end part (32) through which the male contact (5) enters the housing (12), the middle part (30) having a plurality substantially axial oblong openings (34) defining between them flexible blades (36), and the end part (32) continuously surrounding the male contact (5) around the insertion axis (D) in the configuration inserted, - insertion of the male contact (5) in the female contact (10) to put the electrical connector (1) in the inserted configuration, and - displacement of the flexible blades (36) from a curved position, occupied in a non-inserted configuration of the electrical connector (1) and in which the flexible blades (36) are curved radially towards the insertion axis (D), towards a plated position, occupied in the inserted configuration of the electrical connector (1) and in which the flexible blades (36) are pressed against the male contact (5).