Classifications

• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
  • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
  • H01R43/16—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for manufacturing contact members, e.g. by punching and by bending
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
  • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
  • B21C23/00—Extruding metal; Impact extrusion
  • B21C23/02—Making uncoated products
  • B21C23/18—Making uncoated products by impact extrusion
  • B21C23/186—Making uncoated products by impact extrusion by backward extrusion
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
  • B21K—MAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
  • B21K23/00—Making other articles

Definitions

• the invention relates to a method for producing a socket contact from a round rod.
• the invention also relates to a socket contact produced by the method with a hollow cylindrical contact area for contacting a corresponding pin contact and a connection area for connecting an electrical conductor.
• the preparation of the contact elements extensively used in practice is usually carried out by machining a round rod used as a starting material, wherein the contact blades of the socket contacts are made by removing the material webs between the individual contact blades by means of a disc milling cutter. Subsequently, the resulting contact blades of the socket contact are pressed slightly inwards to produce the required spring force.
• This type of making a socket contact is very time consuming, so that the resulting reduced productivity of the manufacturing equipment leads to an increase in the cost of each socket contacts.
• the socket contact is assembled from two components, namely a sleeve closed on one side and a resilient lamella basket, which is inserted into the sleeve and secured thereto.
• the electrical and mechanical contacting of a corresponding pin contact takes place via the contact lamellae of the lamellar cage, which for this purpose has an inwardly bent contact area.
• Such a socket contact is for example from DE 10 2012 001 560 AI known.
• the lamellar basket which is partially arranged inside the sleeve, is bent over the front end of the sleeve onto the outside of the sleeve and fixed to an attachment point.
• An adjustment of the spring force of the lamella basket can be done in the preparation of the socket contact on the choice of the distance of the attachment point from the front end of the sleeve. The farther the attachment point is from the front end, the lower the spring force of the lamella basket.
• the lamella basket itself is made by punching out of a spring strip and then bending the contact blades.
• the disadvantage here however, that through the use of two components, the production of the socket contact is complex and therefore expensive.
• the socket contact is relatively bulky due to the combination of the two components, so that it is unsuitable for compact plug.
• an electrical connection device which consists of three parts, namely a plurality of contact blades having resilient plug contact, a sleeve-shaped receptacle which can be connected to an electrical conductor by crimping, and a retaining sleeve, for locking the connection device in a corresponding mating connector.
• the stamped out of a sheet and bent resilient plug contact is permanently connected via a rivet connection with the sleeve-shaped receptacle.
• the fact that the plug contact, the receptacle and the retaining sleeve are made of different materials, these can each be optimally adapted to their respective purpose. However, this advantage is paid for by the increased complexity and the associated costs in the production of the contact element.
• DE 10 2010 020 346 A discloses electrical contact elements in the form of pin and socket contacts, each having a crimp terminal as a connection region for connecting an electrical conductor, wherein the terminal portion is formed as a hollow cylinder having a slot in the axial direction.
• the contact area is formed by a hollow cylinder, in which wedge-shaped slots are introduced, so that individual spring arms are formed, which serve for contacting an inserted pin contact.
• the present invention has for its object to provide a method for producing a socket contact from a round rod, by which the production time is reduced, so that the productivity can be increased in particular in the mechanical production of socket contacts.
• the hollow-cylindrical contacting region has first and second sections extending in the longitudinal direction of the contacting region, which are formed adjacent to one another in the circumferential direction of the contacting region, wherein the first sections have a thicker wall thickness and the second Sections have a thinner wall thickness
• the method according to the invention is initially distinguished by the fact that, instead of a cutting production, a forming production by means of extrusion and compression molding is provided.
• the contacting region of the socket contact according to the invention has first sections which have a thicker wall thickness, these first sections being connected to one another via second sections having a thinner wall thickness. These bent when folded the first sections outward or folded second portions unfold while a spring action, which acts contrary to a bending apart of the first sections.
• the contact force with which the inwardly employed first sections of the hollow-cylindrical contacting region press against an inserted pin contact is increased.
• the production time for the production of a socket contact can be significantly reduced.
• the productivity ie the number of socket contacts produced within a certain time can be increased so many times compared to the production of socket contacts on a turning or milling machine.
• the production method according to the invention is a non-cutting production method, the material utilization is considerably increased since the starting material is utilized up to 100%. In addition to the lower production time, the material utilization is thus significantly increased in the method according to the invention, so that the individual socket contacts can be manufactured at a lower cost.
• the hollow cylindrical contacting region is preferably produced by means of forward extrusion or reverse extrusion without prior heating of the round rod as the starting material.
• the advantage of cold extrusion is the high dimensional accuracy and the high surface quality of the component produced in this way, so that reworking of the socket contacts produced according to the invention is generally unnecessary. After being ejected from the forming press, the socket contacts thus produced must at most be provided with a coating, but otherwise no longer be processed.
• the round bar is pressed with its first end by backward applied stamping pressure in a die.
• the die which is fixed during the forming process, has the negative mold of the desired hollow-cylindrical contacting area, with the punch and the material moving in the same direction of movement during forward extrusion.
• a die having the negative mold of the desired bonding area penetrates the round rod at the first end. In this case, the material is displaced so that it flows opposite to the direction of movement of the punch in the cavities formed in the stamp.
• the deformation-technical production of the hollow cylindrical contacting region by means of extrusion has the further advantage that the fiber layer in the socket contact is much better adapted to the load case, as compared to a chip-producing production of a hollow-cylindrical contacting device. This is the case.
• compressive residual stresses are introduced into the material by adjusting the first sections inwards, as a result of which the spring effect of the first sections serving as contact lamellae is improved.
• the hollow-cylindrical contacting area previously produced by extrusion is inserted into a die for setting the first sections.
• the die has conically inwardly tapered webs, which are arranged corresponding to the first sections.
• the first sections thus adjust according to the conical taper of the inner cross section of the die, while the second sections with thinner wall thickness compensate for the decreasing circumference of the hollow cylindrical contacting area by bulging outwards.
• corresponding recesses are formed in the matrix between the webs, which allow a corresponding bending or folding of the second sections to the outside.
• a corresponding mandrel is arranged in the hollow-cylindrical contacting region, while this is inserted into the die. This will ensure that the second sections of thinner wall thickness will not fold in or buckle in when the hollow cylindrical contacting area is retracted into the die. During extension of the contacting region from the die, the second sections are pressed by the mandrel into the corresponding recesses of the die, so that the second sections receive a desired, defined contour.
• connection region which is located at the second end of the socket contact, ie at the end facing away from the contacting region.
• a connection region is preferably produced in a first method step by means of extrusion.
• the connection region is preferably formed as a hollow cylinder, wherein the connection region is a crimp connection.
• Such a connection region can also be produced in a simple and cost-effective manner by extrusion, wherein the internal cross-section of the connection region in the be formed in the simplest case circular, with a constant over the length of the connection area diameter.
• connection area in a first method step, i. H. At the beginning of the manufacturing process of the female contact has the advantage that the connection area can then be used in the production of hollow cylindrical Kunststofftechniks Kunststoffes for receiving a punch or thrust bearing during forward extrusion or reverse extrusion.
• a funnel-shaped collar is preferably formed at the outer end of the connection region by widening in a further method step.
• the formation of a funnel-shaped collar facilitates the insertion of a conductor into the connection area.
• the formation of an enlarged, funnel-shaped collar also makes it possible that with an insulated conductor, the end of the conductor insulation protrudes into the collar, while the stripped conductor or the stripped strands are inserted in the hollow cylindrical connection region. As a result, damage to the conductor or strands at the outer end of the connection area can be prevented.
• the aforementioned object is achieved in the case of a bushing contact described in the introduction with a hollow cylindrical contacting region and a connecting region having the features of patent claim 7 in that the hollow cylindrical contacting region has first and second sections extending in the longitudinal direction of the contacting region, alternating in the circumferential direction of the contacting region are formed next to each other.
• the first sections have a thicker wall thickness and the second sections have a thinner wall thickness.
• the first sections of thicker wall thickness are employed inwardly while the second sections of thinner wall thickness are bent or folded outwardly.
• an additional spring force is generated by the convexly curved second sections, with which the first sections are pressed against an inserted pin contact.
• the second sections thus have a similar effect as a mounted on a conventional socket contact over-spring, without this, however, two separate components must be assembled.
• the angle of attack a with which the first sections are made with thicker wall thickness inward, can be adjusted within certain limits, so that on the realized in the manufacture of the socket contact angle of attack can be adjusted to a particular pin contact force acting.
• the angle of attack ⁇ of the first sections is not more than 10 °, in particular not more than 5 °, with the result that the second sections do not have to be bent too much outwards.
• a solid central region is formed between the hollow-cylindrical contacting region and the hollow-cylindrical connecting region.
• This massive central region preferably extends over at least 25% of the total length of the finished female contact.
• the extent of the central region is preferably approximately the same size as the extension of the connection region, while the contacting region preferably has a slightly greater extent than the central region or the connection region.
• at least one stop may be formed on the central region beyond.
• Fig. 2 is a perspective view of an inventive
• Fig. 3 is a longitudinal section through a socket contact according to the invention.
• Fig. 4 shows schematically several intermediate steps in the production
• FIG. 1 shows a perspective view of a pre-geometry of the socket contact 1 according to the invention, ie the socket contact 1 in the not yet completely finished state.
• a hollow-cylindrical contacting region 2 has been produced at a first end 3 of the socket contact 1 or the pre-geometry ⁇ by means of extrusion.
• the hollow-cylindrical contacting region 2 has first sections 4 and second sections 5 extending in the longitudinal direction L, which are formed alternately adjacent to one another in the circumferential direction of the hollow-cylindrical contacting region 2.
• the first sections 4 have a thicker wall thickness di and the second sections 5 have a thinner wall thickness d 2 .
• the wall thickness di of the first sections 4 is substantially thicker than the wall thickness d 2 of the second sections 5, in particular at least twice as thick.
• connection region 7 is formed as a hollow-cylindrical crimp connection at the second end 6 of the socket contact 1, wherein the connection region 7 has also been produced by extrusion.
• the connection region 7 has at its outer end a funnel-shaped collar 8, which has been produced by widening the connection region 7.
• the funnel-shaped collar 8 facilitates the insertion of a conductor to be connected, in particular a stranded conductor, into the connection region 7, before the conductor is firmly and electrically conductively connected to the socket contact 1 by crimping.
• the socket contact 1 also has a mass. Central region 9, which is formed between the hollow cylindrical contacting area 2 and the hollow cylindrical connection area 7. At the central region 9, a stop 10 is formed, which can serve as a stop for fastening the socket contact 1 in a housing wall or a carrier plate.
• Fig. 2 it can be seen that in the finished socket contact 1 shown there, the geometry of the contacting region 2 in comparison to the pre-geometry shown in FIG. 1 is changed.
• the first portions 4 are employed with thicker wall thickness di inwardly, while the second portions 5 are curved with a thinner wall thickness d 2 to the outside or bent.
• the contact force with which the inwardly employed first sections 4 of the contacting region 2 press on an inserted pin contact additionally increases.
• the angle of attack ⁇ of the first sections 4 is drawn, which is preferably less than 10 °, in particular less than 5 °.
• the angle of attack ⁇ is adjustable within certain limits in the production of the socket contact 1, whereby the socket contact 1 and in particular its contact force can be adapted to a pin contact to be contacted.
• Fig. 4 shows various steps in the manufacture of the socket contact 1 of a solid round rod 11 as an output workpiece.
• a first method step while a first punch 12 is pressed at the second end 6 in the round rod 11, whereby the material of the round rod 11 is displaced so that it flows opposite to the direction of movement of the punch 12.
• the hollow-cylindrical connection region 7 is produced in the first method step.
• the outer end of the hollow cylindrical - Lo connecting portion 7 expanded, whereby the funnel-shaped collar 8 is formed.
• the socket contact 1 essentially has a shape or geometry which corresponds to the pre-geometry of the socket contact 1 shown in FIG.
• the contacting region 2 has first sections 4 with a thicker wall thickness di and second sections 5 with a thinner wall thickness d 2 .
• the socket contact 1 with the contacting region 2 is retracted into a die 15 shown in the last illustration of FIG. 4, which has conically tapering webs.
• the webs are arranged corresponding to the first sections 4 of the contacting region 2, so that the first sections 4 corresponding to the conical taper of the inner cross-section of the die 15 make inward.
• the second sections 5 with a thinner wall thickness compensate for the decreasing circumference of the hollow cylindrical contacting region 2 in that they bulge outwards.
• corresponding recesses are formed in the matrix 15 between the webs, which allow the bulging of the second sections 5 to the outside.
• a mandrel 16 is arranged in the hollow-cylindrical contacting area 2 during this method step.
• the mandrel 16 has a geometry similar to that of the stamp 13, so that recesses 17, which receive the first sections 4 of the contacting region 2, are formed in the mandrel 16.
• the mandrel 16 between the recesses 17 formed webs 18, which prevent the second portions 5 of the contacting region 2 buckle during retraction into the die 15 inwardly.
• the second sections 5 When returning the contacting area 2 of the socket contact 1 from the die 15, the second sections 5 are pressed by the mandrel 16 or its webs 18 into the corresponding recesses of the die 15, so that the second sections 5 receive the desired, defined contour. After this manufacturing step, the socket contact 1 is finished and can be provided with a coating if required.

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• Engineering & Computer Science (AREA)
• Mechanical Engineering (AREA)
• Manufacturing & Machinery (AREA)
• Manufacturing Of Electrical Connectors (AREA)
• Forging (AREA)

Priority Applications (4)

Applications Claiming Priority (2)

Publications (1)

Family

ID=60654961

Family Applications (1)

Country Status (6)

Cited By (2)

Families Citing this family (2)

Citations (3)

Family Cites Families (3)

• 2016
  • 2016-12-09 DE DE102016123935.6A patent/DE102016123935B4/de not_active Expired - Fee Related
• 2017
  • 2017-12-06 CN CN201780076009.2A patent/CN110024235B/zh active Active
  • 2017-12-06 WO PCT/EP2017/081668 patent/WO2018104378A1/de unknown
  • 2017-12-06 EP EP17811929.3A patent/EP3552277B1/de active Active
  • 2017-12-06 PL PL17811929.3T patent/PL3552277T3/pl unknown
  • 2017-12-06 ES ES17811929T patent/ES2928090T3/es active Active

Patent Citations (3)

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