GB2288555A

GB2288555A - Adaptor for a plug-in connector and associated plug-in connector

Info

Publication number: GB2288555A
Application number: GB9508125A
Authority: GB
Inventors: Claus Dullin
Original assignee: Amphenol Tuchel Electronics GmbH
Current assignee: Amphenol Tuchel Electronics GmbH
Priority date: 1994-04-21
Filing date: 1995-04-21
Publication date: 1995-10-25
Anticipated expiration: 2015-04-21
Also published as: IT1273592B; DE4413756C1; FR2719166A1; ITMI950805A0; FR2719166B1; GB2288555B; GB9508125D0; ITMI950805A1

Abstract

The connector housing is for admitting a contact set with two conductive tracks (12,14), each having a contact end (12a,14a) for admitting a corresponding wire. Two connector contacts (28,30) and connected to the contact ends by the tracks. An electrical component can be integrated between a contact end (14a) and a connector contact (28). The connector contacts are formed by grating arms with a U-profile. The conductive track connecting sections (V1,V2) the grating (10) are cut through. The housing also admits a cable connectable to the contact ends of the contact set which can be lead out of the housing. The housing is comprises the parts. One part has components for positioning the contact set in the housing.

Description

ADAPTER FOR A PLUG-IN CONNECTOR AND ASSOCIATED PLUG-IN CONNECTOR 2288555

The invention relates to an adapter for a plug-in connector and to the plug-in connector overall. The plug-in connector which receives the adapter in a corresponding casing serves, for example, to provide the electrical connection of an lairbag' such as frequently finds application nowadays in motor vehicles.

In particular in the case where the airbag is arranged in the steering wheel only very little space is available for accommodating the airbag and its connecting parts. To this extent a space-saving design also of the electrical connecting elements is crucial. In this context the use of a flat-conductor ribbon cable has been proposed which, when wound up in a spiral, takes up relatively little space and can also follow movements of the steering wheel.

However, also with this plug-in connector which is known from practice there is a relatively large space requirement.

The object underlying the invention is to demonstrate a way in which a plug-in connector can be designed simply, reliably and in space-saving manner, specifically also in the case where the plug-in connector is equipped with an electrical or electronic component such as a VHF choke. The adapter or plug-in connector is preferably to be designed in such a way that it can also be equipped subsequently with a cable or other components.

The basic idea of the invention is firstly to provide an adapter which contains all the conducting paths and electrical connecting elements. The casing is then suitably tailored to the adapter.

1 2 - In this regard the invention proceeds firstly from the consideration that all the connecting parts and also the necessary plug contacts are formed from a metal sheet that has been pre-manufactured in the form of a lattice.

For the connecting elements this is preferably effected by the formation of crimp contacts. These can easily be formed by bending over suitable sections of metal sheet. Likewise the contacts of the (electronic) component or of the cable to be connected can be soldered, welded or bonded onto the contact zones of the preformed metal sheet. In this case the contact zones of the lattice need not be bent over. The connection can also be effected by means of a penetration method - that is, by deformation of the parts to be connected in a joining process.

The plug contacts are also capable of being deformed insitu from the lattice by, for example, f irstly - in a manner analogous to crimp connections - suitable free end sections of the lattice being f langed before the contact section flanged in this manner is folded by the desired angle in the connecting zone leading to the associated conducting paths.

With all these measures a three-dimensional adapter with all associated connecting elements and plug contacts is formed from a quasi twodimensional lattice.

The concrete shaping of the lattice depends, of course, on the particular application. For an application of the aforementioned type (plug-in connector for an airbag) the lattice may, for example, have two conducting paths which are formed with wider sections at their ends, from which (after bending over) the (crimp) connections are formed. Furthermore, lateral arms can protrude from these conducting paths, so that the connecting ends for the electrical component can be formed here.

Proceeding from the two conducting paths, forked arms (ie, U-shaped in top view) can be formed (on the free ends opposite the connecting ends) which as a result of bending over along the base shank are arranged parallel to one another and with a spacing before they are folded into the desired plug-in position in the connecting zones leading to the particular conducting path.

Connecting sections of the lattice between the conducting paths are then severed, the severing being preferably effected at the manufacturing stage in a corresponding plug-in connector casing which will be described in more detail below.

The adapter according to the invention for a plug-in connector has in its most general embodiment the following characteristics:

at least two conducting paths, each conducting path having a connecting end for receiving a corresponding conductor, at least two plug contacts connected to the connecting ends via the conducting paths and angled downward in relation to the latter, and at least one electrical component capable of being incorporated between the connecting ends and the plug contacts, in which - the adapter is a lattice which has been stamped or cut from a flat metal sheet, and - the plug contacts are formed by additional lattice arms which as a result of bending-over of lateral wider sections of these lattice arms have in cross-section a U-shaped profile and are angled downward in relation to the connecting zones leading to the conducting path, and the sections of the lattice which connect the conducting paths are capable of being severed or are severed.

In comparison with the plug-in connectors mentioned in the Introduction the essential advantages provided by a plug-in connector that is manufactured with an adapter according to the invention are the following:

The lattice can be produced in a simple stamping process in almost arbitrary geometry (depending on the application). In this regard it is not inconvenient if the individual conducting paths and arms and also plugcontact connections are connected to one another, since these connecting points can easily be severed after shaping and manufacture of the lattice.

With a view to shaping and the insertion of components it is furthermore an advantage if several lattices are secured to a base strip by material connection, so that several lattices can be guided alongside one another on such a strip Into a finishing machine. The connecting zones can also be detached easily after manufacture. The casing can be used to this end, as is described below.

The zones where separation takes place may be stamped out; but it is also possible to form intended fracture points at these points at the stage when the lattice is stamped, so that a simple mechanical load is sufficient to sever the individual lattice sections at the desired points.

Where reference is made to 'crimps' this term also encompasses other mechanical reinforcements such as cutting/clamped connections. The plug contacts are formed, as are the remaining connecting elements, directly from the lattice.

A cable can then be connected to the adapter described above, which essentially may be described as being in one piece, before said adapter is manufactured in a casing to form a complete plug-in connector. This may be effected by the manufacturer or by the customer, who needs no special tools for this purpose, as will emerge from the following. So as to conform to the particular characteristics of the adapter, the casing is to have at least two parts, and at least one part of the casing has means for positioning the adapter and/or the cable within the casing. These means serve to place the adapter securely in the casing without the use of screws, rivets or the like - that is, without additional process steps. Rather the intention is for positioning/ locking to be effected directly in the course of assembly of the casing. Furthermore, stresses, in particular tensile stresses on the cable, are to be avoided.

The invention proposes various embodiments for these means, which may be put into effect as alternatives or in combination.

If a flat-conductor ribbon cable is connected, this may have outside the electrical conductors one or more openings through which corresponding arms of the casing grip in the assembled state. With simple means, even in the event of a tensile load on the cable, tearing-off of the connecting point leading to the adapter is prevented.

One or more grooves on the inner surfaces of the casing parts can be used to receive and secure the cable, cable edges or a cable covering. In this regard the groove may also be split, and the two groove sections extend along corresponding casing edges and complement each other after assembly of the casing and secure the cable between them.

The invention also provides for spigots which protrude from the inside of the casing and which serve as a hold- down device for the adapter, which in this way is secured between the free end of the spigot and the associated inner face of the other part of the casing.

An additional spigot can be provided which is designated here as a cutter spigot and which differs from the spigot mentioned above in that it has a cutting edge which during the assembly of the casing serves to sever the intended fracture points in the lattice of the adapter that were described above. Hence the severing process is effected automatically during the manufacture of the plug-in connector.

Openings in the casing serve to enable soldering/welding or other connections to be carried out after assembly of the plug-in connector, for which reason the openings are to be arranged where the adapter is connected to associated parts. It is precisely this characteristic which also serves to enable insertion of additional components by the user.

So far the lattice may remain in one piece and cables do not yet need to be connected. The user now proceeds, for example, as follows. He connects a cable, fits a casing part and solders, welds or joins the connecting zones.

The casing opening or openings serve to accommodate auxiliary tools. Then he closes the casing. When the casing parts are pressed together the intended fracture points in the lattice are severed automatically. The casing openings can then be sealed by stoppers.

Further characteristics of the invention will emerge from the characteristics of the subclaims and the other application documents.

The invention will be elucidated in greater detail below on the basis of an embodiment. Illustrated in this regard, in very schematic form in each case, are:

Figure 1: a pre-stamped lattice with galvanic surface, Figure 2: the lattice after an initial pre-assembly, Figure 3: the lattice after being equipped with an HF choke, in each case in top view, Figure 4: the adapter in the state according to Fig. 3 in a side view, Figure 5: a top view of the finished manufactured adapter after severing of bridges between the conducting paths, Figure 6: a lower part of the casing for the adapter according to Figs. 1 to 5, Figure 7: an upper part of the casing for the adapter according to Figs. 1 to 5, Figure 8: a section through a plug-in connector, Figure 9: a top view of an adapter with connected flatconductor ribbon cable.

With a view to producing an adapter, firstly a lattice 10 is stamped out from a metal sheet, and Figure 1 depicts the geometry chosen here by way of example.

The lattice 10 consists essentially of two conducting paths 12, 14 with connecting ends 12a, 14a connected to a strip 18 via crosspieces 16.

The connecting ends 12a, b have lateral projections x, y, in which the projections x have essentially rectangular shape and the projections y have roughly trapezoidal shape.

From the conducting paths 12, 14 there further protrude arms 20, 22, the free ends of which have a width which is greater than that of the connecting crosspieces 24 leading to the conducting paths 12, 14.

Located opposite the connecting ends 12a, 14a the conducting paths 12, 14 each have forked extensions 28, 30. As Figure 1 shows, the extensions 28, 30 have a roughly U-shaped profile in top view with two free shanks, 28a and 30a respectively, and a connecting shank, 28b and 30b respectively.

The connecting ends 12a, 14a serve to connect the adapter to corresponding cable strands (not shown here). For this purpose the lateral projections x, y are bent over in the manner of a crimp-type seal, so that the stranded wires can later be inserted and crimped.

The arms 20 and 22 and the extensions 28 and 30 are bent over in similar manner (around the connecting shanks 28b, 30b). In top view the shanks, 28a and 30a respectively, are then located in pairs above one another, whereas the lateral sections of the arms 20, 22 and, respectively, the bilateral projections x, y extend more or less parallel to one another (out of the plane of the drawing), as shown in Figure 2.

In the next assembly step the extensions 28, 30 are bent downwards (by about 900) around the connecting zones leading to the conducting paths 12, 14 and an HF choke 32 with its connecting arms 32a, 32b is firmly crimped on the arms 20, 22 (Figures 3, 4).

In the final working step the cable strands 34a, b are finally secured with the aid of the connecting ends 12a, 14a. In addition the crosspieces 16 and the connecting zones V1, V2 are severed between the conducting paths, so that a geometry arises such as shown in Figure 5.

The conducting path 14 then extends from the cable strands 34a to the arm 20 on which one end of the HF throttle 32 is firmly crimped, the other end of which extends in the direction of the arm 22 which continues via a part of the conducting path 12 to the extension 28 (plug contact).

From the additional extension 30 (2nd plug contact) an electrical connection extends via a section of the conductor path 14 and an adjacent section of the conducting path 12 to the connecting end 12a and thereby to the cable strand 34b.

The adapter pre-manufactured in this manner with an electrical component can be produced in an automatic assembly unit and then manufactured in an appropriate casing. The described construction of the adapter enables a space-saving shape and thereby also its application in, for example, a plug-in connector for the connection of an airbag or belt-tensioning device, in which, as is well-known, very little space is available.

The connecting crosspieces between the conducting paths stabilise the lattice in the course of assembly but can then be severed just as easily in order to provide the desired electrical paths. In this regard the severing of the connecting crosspieces is preferably effected in the manner described below.

Figures 6 and 7 show a two-part casing (50u, 50o) for receiving the adapter described. On the inner face of the upper half 50o a cutter spigot 52 is formed which is pointed at the free end so that it severs the described intended fracture points V1 and V2 of the lattice 10 in the course of assembly of the casing (connection of the casing parts).

In addition a spigot 54 can be discerned which also protrudes from the inside of the upper part of the casing 50o. This spigot 54 has the function of a hold-down device, for instance in the course of severing of the lattice 10 in the region of the sections V1 and V2. Its front face is therefore flattened and its length is such that it rests directly on the lattice 10 in the assembled state, whereas the lattice 10 is supported with the other side on the casing half 50u.

Represented in the casing parts 50u, o in purely schematic manner are bores 56, the task and function of which has already been described above.

Upper and lower halves 50o, u are detachably engaged at their ends via engaging means 58 in a manner known as such.

Figure 8 shows the plug-in connector in the assembled state. In conjunction with Figure 9 it can be seen that the connecting ends 12a, 14a are connected to a flatconductor ribbon cable 60 which has two central recesses 62 through which arms 64 grip which, like the spigots 52, 54, protrude from the upper casing half 50o on the inside and here have the shape of a cone. Correspondingly the lower casing half 50u has associated recesses 66.

The cable 60 is extrusion-coated with plastic, and the protective covering 68 formed in this way protrudes at the edge and in the same way as lateral hooks 70 on the adapter is guided in corresponding grooves of the casing which, for the sake of better comprehension, are not represented here in any detail.

Claims

1. Adapter for a plug-in connector with at least two conducting paths (12, 14), each conducting path (12, 14) having a connecting end (12a, 14a) for receiving a corresponding conductor (34a, 34b), at least two plug contacts (28, 30) connected to the connecting ends (12a, 14a) via the conducting paths (12, 14) and angled downward in relation to the latter, and at least one electrical component (32) capable of being incorporated between the connecting ends (12a, 14a) and the plug contacts (28, 30), in which the adapter is a lattice (10) which has been stamped or cut from a flat metal sheet, and the plug contacts (28, 30) are formed by lattice arms which as a result of bending-over of lateral wider sections (28a, 30a) of these lattice arms have in cross-section a U-shaped profile and are angled downward in relation to the connecting zones leading to the corresponding conducting path (12, 14), and the sections (V1, V2) of the lattice (10) which connect the conducting paths (12, 14) are capable of being severed or are severed.

2.

Adapter according to Claim 1, in which the connecting ends (12a, 14a) are isolated by severing of a common connecting strip (18) of the lattice (10).

3. Adapter according to Claim 1 or 2, in which the electrical component (32) is connected with its first end (32a) to a connecting element (20) of a lattice arm which itself is directly connected to the connecting end (14a) of a first conducting path (14) and the electrical component (32) with its second end (32b) Is electrically connected via an additional connecting element (22) to a plug contact (28) and an additional plug contact (30) has a direct electrical connection to a connecting end (12a) of a second conducting path (12).

4. Adapter according to one of Claims 1 to 3, in which the electrical component (32) is an HF screening choke.

5. Adapter according to one.of Claims 1 to 4, in which the plug contacts (28, 30) extend at an angle of 90 in relation to the conducting paths (12, 14).

6. Adapter according to one of Claims 1 to 5, in which the surface of the lattice (10) is galvanised.

7. Adapter according to one of Claims 1 to 6, in which the sections (V1, V2) of the lattice (10) have intended fracture points.

Plug-in connector, consisting of an adapter according to one of Claims 1 to 7, a casing (50) for receiving the adapter and at least one cable (60) connected to the connecting ends (12a, 14a) of the adapter, in which said cable is guided out of the casing (50), in which the casing (50) consists of at least two parts (50u, o), and at least one casing part (50o) has means (52, 54, 56) for positioning the adapter and/or the cable (60) within the casing (50).

1 9. Plug-in connector according to Claim 8, in which the cable (60) is a flat-conductor ribbon cable which has outside the conductors or between the conductors at least one recess (62) which is penetrated by a protruding arm (64) on the inside of a casing part (50o) in the assembled position.

10. Plug-in connector according to Claim 8 or 9, in which the means consist of at least one groove on the inside of at least one casing part, in which the cable (60) or a protective covering (68) extending around the cable (60) is located in interlocking manner.

11. Plug-in connector according to one of Claims 8 to 10, in which the means consist of at least one spigot (54) projecting from an inner face of a casing part (50o) which secures the adapter resting on the other casing part (50u).

12. Plug-in connector according to one of Claims 8 to 11, in which the means consist of at least one cutter spigot (52) projecting from an inner face of a casing part (50o), the f ree end of said cutter spigot being pointed, in which the cutter spigot (52) is arranged in the region of the sections (V1, V2) of the lattice (10) to be severed and in the assembled position rests on the opposite casing part (50u).

13. Plug-in connector according to one of Claims 8 to 120 in which the casing (50) has openings (56) in the region of the connecting ends (12a, 14a) and/or connecting elements (20, 22).