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
  • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
  • B21J5/00—Methods for forging, hammering, or pressing; Special equipment or accessories therefor
  • B21J5/06—Methods for forging, hammering, or pressing; Special equipment or accessories therefor for performing particular operations
  • B21J5/068—Shaving, skiving or scarifying for forming lifted portions, e.g. slices or barbs, on the surface of the material
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
  • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
  • H01R13/02—Contact members
  • H01R13/10—Sockets for co-operation with pins or blades
  • H01R13/11—Resilient sockets
  • H01R13/113—Resilient sockets co-operating with pins or blades having a rectangular transverse section
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
  • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
  • B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass

Definitions

• the present invention relates to a contact element for transmitting an electric current having a contact body which has a contact surface, on which at least one contact lug is arranged that protrudes in sections from the contact surface.
• the present invention further relates to a method of manufacturing such a contact element from a contact body.
• High-current conductors for example ground straps or busbars, are used for this purpose. These conductors have contact elements with a large contact surface for transporting large currents.
• the resistance of the contact system between the components should be as low as possible so that the voltage drop across the contact system is as low as possible.
• the connection at the contact system is vibration-resistant. To compensate for vibrations and keep the transmission resistance between the contact elements of a contact system as low as possible, contact elements are either positively connected or pressed against each other with a spring force.
• this problem is solved in that a contact section of the contact body is cut off essentially parallel to the contact surface and a contact lug is formed by the cut off contact section, one end of which is monolithically connected to the contact body.
• Such a contact element can be provided by the method according to the invention.
• This method of manufacturing a contact element comprises the following steps: providing a contact body having a contact surface; and cutting off a contact section from the contact body substantially parallel to the contact surface to produce at least one contact lug on the contact surface.
• the method according to the invention and the contact element manufactured with it make it possible to dispense with a two-part construction with a rigid contact body and a contact spring or lug welded to it, and instead to provide a one-part contact element in which the contact body is monolithically connected to one end of the contact lug.
• the contact lug is thus integrated into the contact body. This integration transmits high currents with lower resistance because there is no additional resistance due to the connection of the two parts.
• the contact element according to the invention is of simple construction and easy to manufacture.
• a separate spring element, which is mounted on a contact body and fixedly connected to it at the desired location, is not required due to the monolithic configuration according to the invention.
• the cutting off of a contact section from the contact body offers great flexibility with regard to the arrangement, geometry and alignment of the contact lug, which will be discussed in more detail below.
• Cutting off is understood to mean a manufacturing method in which the shape of the contact body is eliminated by removing the material cohesion at the processing point (cut-off surface).
• “Cutting off” in the sense of the present invention does not mean complete cutting off such that the cut off contact section is completely cut off from the rest of the contact body.
• the cutting line, zone or cut-off surface ends in the contact body and is thus not completely closed, so that one end of the contact lug is monolithically connected to the contact body.
• the step of cutting off can be performed by dividing, for example trimming, splitting, tearing, breaking, peeling, or chiseling.
• Cutting off by ablation for example of a thermal or chemical nature by means of methods such as flame cutting, laser ablation or plasma fusion cutting, is also possible.
• the decisive factor is that the cutting off process results in an "incision" (without this being restricted to the cutting off process of trimming) parallel to the contact surface, thereby producing a contact lug, one end of which is monolithically connected to the contact body.
• a “contact lug” is a strip-, plate- or band-shaped protruding element that is monolithically connected to the contact body on one side.
• the contact lug which could also be called a contact tongue, has a certain thickness, width and length.
• the length of the contact lug is measured from its end monolithically connected to the contact body, the proximal end, to its free, distal end.
• the thickness of the contact lug is dimensioned by the cut-off height, i.e. the distance from the contact surface of the contact body to the cutting line along which the contact section is cut off parallel to the contact surface.
• the width of the contact lug is the remaining third spatial dimension, which extends perpendicular to the plane formed by the longitudinal axis and the thickness direction.
• the contact lug protrudes from the contact surface.
• a region of the manufactured contact lug protrudes from the cubature of the contact body as it is present before the step of cutting off.
• the contact lug forms an elastically deflectable contact spring, for example in the form of a spring tongue.
• the free, distal end of the contact lug can, but does not have to, protrude from the contact surface, which will be discussed below in exemplary embodiments.
• the contact body can have a flat contact surface.
• the contact body can be a contact plate or a contact strip, with the contact surface being present on one surface of this body.
• Such a contact body can also be provided easily, for example by punching, and is well suited to transmitting high currents due to its solid shape.
• the contact body can thus be a punched part, for example.
• the length of the contact lug can be multiple times greater than the width and thickness of the contact lug.
• the contact lug can be two, three, five or ten times longer than wide.
• the cut-off direction corresponds to the direction along which the contact section is cut off parallel to the contact surface, starting from an edge or shoulder of the contact section.
• the spatial extent of the cut-off surface in the cut-off direction, relative to the spatial extent of the contact body in this direction, can be more than 25%, for example 25% to 45% or 60% to 85%.
• the method according to the invention allows great flexibility with regard to the geometry of the contact lug produced.
• the cut-off depth defines the length of the contact lug.
• the cut-off height defines the thickness of the contact lug, and the width of the contact lug can also be selected almost arbitrarily, which will be discussed in more detail below.
• the contact lugs can be arranged at any position on the contact body and aligned as desired.
• the contact body may be a contact strip, wherein the contact lug extends transversely to the longitudinal direction of the contact strip.
• the longitudinal direction is the greatest spatial extent of the contact strip.
• the contact lug may extend from its proximal end, which is monolithically connected to the contact body, to its free distal end transversely perpendicular to the longitudinal direction of the contact strip. It is also possible to manufacture the contact lugs on an end face, i.e. a lateral edge of a contact strip or plate. It is possible, for example, to manufacture the contact lugs on opposite side edges of a contact strip. In this case, a flat contact is obtained in which the contact tongues protrude on one end face, on both sides and parallel to the longitudinal direction.
• At least one groove may be formed in the contact surface prior to the step of cutting off.
• the contact surface may be flat. It can be grooved by stamping or pressing. Also by material removal, for example lasing, milling or the like, a groove can be formed in the form of a linear depression, similar to a channel.
• the groove in the contact surface can delimit the contact section.
• a U-shaped channel can be formed in the contact surface, which delimits the contact section.
• the groove can specify the cut-off direction and/or the cut-off or incision depth and facilitate the subsequent cutting of the contact section to produce the contact lug.
• the groove may provide a guide or orientation for a cutting tool.
• the contact section can be cut off parallel to the contact surface.
• the depth of the groove can define the thickness of the contact lug.
• ribs or beads may be formed protruding from this opposite side.
• a groove on the contact surface can be aligned with a rib on the opposite side.
• the ribs may be formed simultaneously with the grooves, for example by stamping or pressing. The material stamped into the grooves is then formed into ribs in a controlled manner. These ribs are functional, which will be discussed subsequently, and it is avoided that the displaced material escapes in other directions and forms the contact in a detrimental way, e.g. warps or elongates it.
• the grooves can be created via material removal, such as a milling or etching process.
• These ribs may form attachment elements to secure the contact element at a particular point, for example to latch it.
• the ribs enlarge the surface of the contact element, which improves heat dissipation from the contact element.
• the ribs provide stiffening zones. These stiffening zones can limit forming of the contact body to certain directions.
• the contact element can have several contact lugs.
• the contact lugs can be arranged laterally next to each other.
• Contact lugs are arranged laterally next to each other if their longitudinal axes run essentially parallel to each other.
• the connection points at which the contact lug is monolithically connected to the contact body can be on the same side in the case of adjacent contact lugs, so that the free ends of the adjacent contact lugs also point in the same direction.
• adjacent contact lugs the free ends of which point alternately in different, e.g. opposite, directions, are also possible.
• Contact lugs arranged side by side can be produced, for example, with an embodiment of the method in which parallel grooves are formed in the contact surface.
• a contact section is formed between two adjacent grooves, from which a contact lug can be cut off.
• the contact body can be divided between two grooves parallel to the contact surface.
• the cutting line or cut-off surface can connect two adjacent grooves during this cutting.
• the grooves are formed before the contact lugs are cut off. This allows individual lugs to be produced directly during cutting off.
• the grooves are at least as deep in the material as the cut-off height.
• the grooves provide better manufacturing conditions. For example, it is possible to work with a larger cutting tool that produces individual contact lugs or tongues. Another advantage is that the grooves give the contact lugs a clean lateral boundary.
• the contact lugs arranged next to each other are directly cut off from each other, and the possibility of the material tearing out laterally in an undefined manner is eliminated.
• the contact section which lies between two parallel grooves, is still connected to the contact body at two surfaces.
• One of these surfaces lies parallel to the contact surface inside the contact body and extends between two adjacent grooves. If this connection is cut off, for example along a cut-off surface which is parallel to the contact surface and ends in the two grooves, a contact lug is obtained which is now only monolithically connected to the contact body at its second connection surface, which is opposite the free end of the contact lug.
• the thickness of the contact lug can be set via the groove depth
• the width of the contact lug can be specified via the distance between the parallel grooves.
• the length of the contact lug can be specified via the length of the grooves.
• the grooving of a contact surface can thus specify the dimension of the contact section and the contact lug made from the contact section.
• the grooving facilitates the step of cutting off, because this only requires the formation of a flat cut-off surface.
• contact lugs may be arranged one behind the other.
• Contact lugs are arranged one behind the other if their longitudinal axes are aligned with each other.
• their ends monolithically connected to the contact body can lie together and their free ends point away from each other, for example in opposite directions. Configurations are also conceivable in which the free end of a contact lug is adjacent to an end of the contact lug behind it that is monolithically connected to the contact body.
• Contact lugs arranged one behind the other can also be easily produced using an embodiment of the method according to the invention, in which the contact body is provided with at least one groove in the contact surface prior to the step of cutting off.
• the contact body can be cut off from the opposite groove ends, along the groove parallel to the contact surface.
• the cut-off direction of one contact lug can point in the opposite direction to the cut-off direction of the other contact lug, thus creating a common connection area between the two contact lugs, with one end of each contact lug monolithically connected to the contact body.
• the contact lugs located one behind the other extend from the common connection area, in opposite directions.
• the contact body may have an attachment collar to which the contact lug or, in the case of several contact lugs, several, for example all, contact lugs are monolithically connected.
• the contact lugs protrude from the attachment collar of the contact body.
• an attachment collar is meant an elongated projection. This projection can be beam-shaped, for example.
• a side wall of this attachment collar, which runs transversely to the contact surface of the contact body, can be monolithically connected to one or more contact lugs.
• an attachment collar can be formed by forming several parallel grooves in the contact surface, which, for example, completely traverse the contact surface in a spatial extension. Subsequently, in the step of cutting off, contact lugs can be made from the contact sections lying between two grooves. If the incision depth parallel to the contact surface is approximately the same in each case during cutting, an attachment collar is formed in the contact element. This then runs perpendicular to the previously formed grooves. If the contact lugs are all cut off along the same cut-off direction starting from the same edge of the contact body, a contact element is formed with a row of adjacent contact lugs. It is also possible to form two rows of adjacent contact lugs, with the lugs of the two rows lying one behind the other.
• contact lugs could be made from opposite edges of the contact body by cutting them off in opposite cut-off directions.
• the attachment collar is located between the cut-off surfaces.
• the contact lugs of the two rows protrude from the attachment collar in different directions. They would be monolithically connected to different, opposing side surfaces of the attachment collar.
• the at least one manufactured contact lug can be formed/shaped.
• the contact lug may be bent so that its free end points toward the contact body.
• the contact lug such that it is bent over, may have a central portion between the proximal and distal ends that protrudes from the cubature of the original contact body.
• the proximal and distal ends of the contact lug may both be located in the original cubature of the contact body.
• the free end of a reshaped contact lug can be supported on the contact body. The free end thereby provides another point of support for the resilient contact lug, which can improve the spring properties.
• a second electrical contact point is created, which reduces the electrical resistance of the contact element and improves thermal conductivity.
• At least one contact lug can be metallically coated.
• the coating may be electroplated.
• the coating can comprise silver, gold, tin, nickel or another metal or metal alloy.
• a support element may be arranged between a contact lug and the contact body.
• This support element for example a support spring, can improve the spring force of the contact element. This makes it possible, even in the case of a contact body made of a material from which contact springs formed are very good electrical conductors but less elastically formable, to achieve sufficient spring force to withstand even the strong vibrations in the automotive sector.
• the contact body can be finally formed/shaped and thereby, a contact socket can be formed.
• the correspondingly manufactured contact element has a contact socket and at least one contact surface lies in the socket, i.e. the contact surface with the manufactured contact springs lie in the interior of the socket.
• the contact body can be bent back onto itself.
• Two contact surface areas spaced apart from each other can be provided on one surface of the contact body.
• at least one contact lug can be monolithically connected to the contact surface.
• a contact element with a contact socket can be provided in which both contact surface areas are located in the interior of the socket.
• the contact body can be formed between the two contact surface areas in such a way that the two areas point towards each other and are arranged spaced apart from each other by a predetermined distance in the interior of the socket.
• Fig. 1 a perspective view of an embodiment of cutting off a contact section from the contact body to produce a contact lug on the contact surface;
• Fig. 2 a top view on the contact surface of Fig. 1 ;
• Fig. 3 a side view of Fig. 1 viewed in the cut-off direction;
• Fig. 4 a side view of the manufactured contact element after the step of cutting off from the same view as Fig. 3;
• Fig. 5 a side view of the manufactured contact element of Fig. 4, viewed perpendicular to the cut-off direction;
• Fig. 6 the step of providing a contact body according to a further embodiment of a further method of manufacturing a contact element
• Fig. 7 the provided contact body of Fig. 6 after parallel grooves have been formed in the contact surface
• Fig. 8 an enlarged view of the grooves formed in Fig. 7;
• Fig. 9 a side view of a manufactured contact element after a contact section has been cut off from the contact body of Fig. 7 and a contact lug has been manufactured on the contact surface;
• Fig. 10 a schematic side view of the contact element according to Fig. 9 after the manufactured contact lug has been formed
• Fig. 11 an alternative embodiment of a contact element made from the contact body of Fig. 7 with contact lugs arranged one behind the other;
• Fig. 12 a schematic representation of the contact element according to Fig. 11 after the manufactured contact lugs have been formed
• Fig. 13 a schematic side view of two contact lugs of Fig. 12, one behind the other and formed;
• Fig. 14 the contact element of Fig. 13, from a schematic side view, analogous to the representation in Fig. 13, after a support element has been arranged between the contact lugs and the contact body;
• Fig. 15 a manufactured contact element of a further embodiment, wherein the contact body of the contact element according to Fig. 12 is formed into a contact socket.
• a first embodiment of the method is shown in Figs. 1 to 3.
• the contact element 1 manufactured by this method is shown in two different side views in Figs. 4 and 5.
• the method of manufacturing the contact element 1 comprises the step of providing a contact body 2 having a contact surface 3.
• the contact surface 3 may be a flat surface of the contact body 2.
• the contact body 2 is a contact plate 4.
• the contact surface 3 is one of the large plate sides.
• the thickness 5 of the contact plate 4 corresponds to the height of the contact body 2.
• a contact section 6 is cut off from the contact body 2 essentially parallel to the contact surface 3 and at least one contact lug 7 is manufactured in the process.
• This contact lug 7 is monolithically connected to the contact body 2 at one end, its proximal end 8. At its distal end 9, the free end of the contact lug 7, which is opposite the connected proximal end 8, the separated contact lug 7 protrudes from the contact surface 3, as can be seen in Figs. 4 and 5.
• the separation surfaces along which the contact section 6 is cut off from the contact body 2 to produce the contact lug 7 are shown as dashed lines in Figs. 1 to 3.
• the separation direction 10 along which a cutting tool 11 is moved for the step of cutting off is shown by arrows and other symbols in Figs. 1 to 3.
• the cut-off lines, which in the embodiment of Figs. 1 to 5 are defined by the shape of the cutting tool, determine the geometry of the manufactured contact lug 7.
• the cut-off depth 12 which could also be called the incision depth, indicates how far the cutting tool 11 cuts into the contact body 2 in the cut-off direction 10 from one side edge 13 of the contact body 2.
• This cut-off depth 12 corresponds to the length 11 of the manufactured contact lug 7.
• the cut-off height 14 is the distance from the cut-off surface 6 to the contact surface 3.
• the cut-off height specifies the thickness D of the contact lug 7.
• the cut-off distance 15, the width of the cutoff surface 6, determines the width B of the contact lug 7.
• the cutting tool 11 is shown as a wedge-shaped splitting tool, so that during the step of cutting off, the free, distal end 9 of the contact lug 7 is simultaneously bent out of the contact surface 3.
• An elastically deflectable contact lug 7 is produced which acts as a contact spring or spring tongue and is suitable for pressing the manufactured contact element 1 against another component (not shown) to which current is to be transmitted.
• the integrated, monolithic design of the contact element 1 according to the invention results in a particularly low electrical resistance.
• the spring effect of the contact lug 7 ensures good contact pressure, which increases the electrically current-transmitting contact area, and compensates well for vibrations such as those that can occur in the automotive sector.
• the contact lug 7 is produced by cutting off a contact section 6 parallel to the contact surface 3 of the contact body 2. Due to the parallel cut-off direction 10, the length L of the contact lug 7 is basically limited only by the geometric dimensions of the contact body 2 along the cut-off direction 10.
• the contact plate 4 has, for example, a spatial extent 16 along the cut-off direction 10.
• the length L of the contact lug 7 may have at least 25% of the spatial extent 16, preferably more than 40% of the spatial extent 16.
• the method according to the invention can be used to manufacture contact elements 1 , the contact lugs 7 of which are many times longer than they are wide and thick.
• the length L of the contact lug 7 can be at least twice, at least three times, at least five times or at least ten times as long as the width B of the contact lug 7.
• the length L of the contact lug 7 may be longer than its thickness D by an even greater factor.
• the angle a at which the contact lug 7 projects from the contact surface 3 can be selected as desired. This angle can be adjusted to the requirements with regard to the spring force as well as the spatial dimensions that the manufactured contact element 1 must fulfill. In particular, the angle a can be smaller than 30°.
• the exemplary method again comprises the step of providing a contact body 2 with a flat contact surface 3.
• a punched part 17 is provided as the contact body 2.
• the punched part 17 is in the form of a contact strip 18 or band with a defined width 19 and thickness 20, in each case perpendicular to the longitudinal direction 21 of the contact strip 18.
• grooves 22 are formed in the contact surface 3 of the contact strip 18.
• two groups of parallel grooves 22 are formed in different areas of the flat contact surface 3.
• the parallel grooves run transversely, more precisely perpendicular to the longitudinal direction 21 of the contact strip 18 and parallel to each other.
• Each groove 22 penetrates the contact surface 3 over the complete width 19 of the contact strip 18 and runs in a straight line, perpendicular to the longitudinal direction 21.
• the grooves 22 may, for example, be stamped or pressed in.
• the grooves 22 are formed with a rectangular cross-section.
• Each groove 22 comprises a groove bottom 23 and lateral groove walls 24 extending substantially perpendicularly from the contact surface 3 to the groove bottom 23.
• the configuration of the grooves 22 by stamping or pressing may be accompanied by forming of the side 25 of the contact body 2 which is opposite to the contact surface 3.
• ribs or beads 26 can be formed on the opposite side 25 projecting therefrom. These ribs 26 can be preferred to fix the contact element 1 at a certain position, for example to latch it.
• the ribs 26 also provide a larger contact area and can compensate for unevenness, which can improve current transmission.
• the ribs 26 increase the surface area, which may improve heat dissipation from the contact element 1.
• the ribs 26 provide stiffening of the contact strip 18. The stiffening ribs 26 make torsion and folding of the contact strip 18 about or along its longitudinal axis/longitudinal direction 21 more difficult. Folding of the contact strip 18 about a folding axis in the direction of the width 19 of the contact strip, i.e. parallel to the ribs 26, is still possible, which will be discussed in detail later.
• the grooves 22 can be manufactured with a certain groove depth 27, which extends from the contact surface 3 to the groove bottom 23.
• the groove depth 27 can specify the thickness D of the contact lugs 7.
• a contact section 6 is formed between two grooves 22.
• the step of cutting off can provide that the contact section 6 is cut off, for example incised, parallel to the contact surface 3 along the width direction 19 of the contact strip 18, starting from the edge.
• the cut-off direction 10 is indicated in Figs. 7 to 10.
• the cut-off surface or cut-off line may thereby connect two adjacent grooves 22.
• the cut-off line can, for example, be aligned with the groove bottoms 23 of two adjacent grooves 22.
• a contact lug 7 can be produced, the proximal end 8 of which is monolithically connected to the contact surface 3 and the free end 9 of which protrudes from the contact surface 3.
• the manufactured contact lug 7 of Fig. 9 corresponds essentially to the contact lug 7 of Figs. 4 and 5.
• the manufactured contact lug 7 can be formed in a further method step.
• the formed contact lug 7 is shown in the schematic side view in Fig. 10.
• the contact lug 7 can be bent.
• the free end 9 of the contact lug 7 was bent so that it points to the contact body 2, specifically its contact surface 3.
• the free end 9 of the contact lug 7 is supported on the contact surface 3.
• the proximal end 8 is supported on the contact body 2, specifically its contact surface 3, due to its monolithic connection and the distal end 9 is supported on the contact body 3 due to its forming.
• the contact lug 7 forms a leaf spring which is supported at both ends.
• the bearing at both ends of the contact lug 7 has the advantage, on the one hand, that a higher spring force can be generated as a result. Furthermore, there is electrical contact at each of the supported ends 8, 9 and thus better current transmission overall.
• An embodiment of the contact element 1 not shown in the Figures is obtained when a contact lug 7 of the shape shown in Fig. 9 or Fig. 10 is produced from each of the contact sections 6 between two adjacent grooves 22 by the step of cutting off and, if necessary, forming.
• a contact element 1 is obtained in which a plurality of contact lugs 7 are arranged in a row laterally adjacent to each other. Specifically, the contact lugs would be arranged next to each other in the longitudinal direction 21 and would form a contact lug row. In this way, the spring force can be transmitted over a larger area of the contact element 1.
• the manufactured contact element 1 of this embodiment has contact lugs 7 arranged one behind the other. Specifically, the contact lugs 7 are arranged one behind the other perpendicular to the longitudinal direction 21 of the contact strip 18. Contact surfaces 3 with two rows 29, 30 of contact lugs 7 are formed.
• the contact sections 6 between two adjacent grooves 22 are first cut off along the cut-off direction 10, analogous to the embodiment shown in Figs. 7 to 9, and a first row 29 of adjacent contact lugs 7 is formed.
• the cut-off depth 12 or incision depth along the cut-off direction 10 is smaller. While the incision depth 12 in the example of Fig. 9 is about 85% of the width 19 of the contact strip 18, the incision depth 12 in the cut-off direction 10 in the embodiments of Figs. 11 to 15 is less than 50%, for example between 30% and 45% of the width 19 of the contact strip 18.
• a second row 30 of contact lugs 7 is produced by cutting off the contact sections 6 analogously from the opposite side edge of the contact strip along a cut-off direction 10' which is opposite to the cut-off direction 10, i.e. by cutting in between two adjacent grooves 22 in the cut-off direction 10'.
• pairs of two contact lugs 7 arranged one behind the other are obtained in the two rows 29, 30.
• the monolithically connected ends 8 of each pair lie together and the free ends 9 of the two contact lugs 7 point away from each other in each pair.
• An attachment collar 31 is formed between the first row 29 and the second row 30 of contact lugs 7, to which the contact lugs 7 are monolithically connected.
• the attachment collar 31 extends substantially in the longitudinal direction 21 of the contact strip 18.
• the monolithic connection of the contact lugs 7 takes place at side walls 32 of the attachment collar 31 , which are substantially perpendicular to the contact surface 3. Viewed in the longitudinal direction 21 , the attachment collar 31 thus has a substantially rectangular cross-section.
• the contact lugs 7 can be formed as shown, for example, in Fig. 10.
• the resulting contact lugs 7 are shown schematically from the side in Fig. 13.
• a support element 33 may be arranged between a contact lug 7 and the contact body in another exemplary embodiment.
• the support element 33 can be formed as a support spring 34.
• the contour and shape of the support element 33 can be adapted to the contour and shape of the corresponding contact lug 7 with which it is associated. This is shown schematically in Fig. 14. By suitable selection of the material as well as the shape of the support element 33, the contact element 1 can be given the desired spring force-applying property in its contact surface 3.
• the contact element 1 as shown in Fig. 14 for example, is formed.
• the contact body 2 is formed in such a way that a contact socket 35 is formed.
• the contact body 2, for example the contact strip 18 can be formed, for example bent over, in defined forming zones 36, 37.
• the bending axis 38 about which bending is performed runs essentially perpendicular to the longitudinal axis 21 , in the direction of the width 19 of the contact strip 18. This bending is not prevented by the stiffening ribs 26.
• Two walls are formed from the forming zones 36, 37, which limit the contact socket 35 in the longitudinal direction 21 . Between the walls of the forming zones 36, 37 extend areas of the contact surface 3 in which contact lugs have been made.
• the section lying between the forming zones 36, 37 is bent back onto the contact strip 18 and, after forming, lies parallel to and spaced apart by the length of the forming zone 36, 37 above the remaining contact strip 18.
• connection projections 40 can be inserted into complementary connecting receptacles 41 of the contact strip 18 and fixed there. This forming results in the contact socket 35, which is shown in Fig. 15.
• the interior 42 of this contact socket 35 is accessible only in the direction of the width 19 of the contact strip 18. Areas of the contact surfaces 3 with contact lugs 7 are arranged in the interior 42.
• the first area is located between the two forming zones 36 and 37.
• the second contact surface area is located between the forming zone 36 and the connecting receptacles 41.
• the two contact surface areas are arranged parallel to each other within the contact socket 35 in the interior 42 of the contact socket, with contact lugs 7 facing each other.
• a flat contact can be inserted into the interior 41 of the contact socket 35 and electrically contacted with the contact areas 3, with the contact lugs 7 contacting such a flat contact from both sides/areas and holding it in a vibration-protected manner.

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• Engineering & Computer Science (AREA)
• Mechanical Engineering (AREA)
• Manufacturing & Machinery (AREA)
• Contacts (AREA)
• Coupling Device And Connection With Printed Circuit (AREA)

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• 2021
  • 2021-10-27 DE DE102021128007.9A patent/DE102021128007A1/de active Pending
• 2022
  • 2022-10-26 WO PCT/EP2022/079859 patent/WO2023072982A1/en unknown

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