Contact element, plug connector having a contact element and plug connector arrangement having a plug connector

Abstract

The invention relates to a contact element (100) having a plug-in section (200) which is deformed from a wire end (210) of an electrical conductor (220), in particular of an electrical stranded conductor, and having two opposite, in particular pointing away from one another, in particular flat plug-in section contact surfaces (201), and having a contact sheet clip (300) which is fastened at the plug-in section (200). The contact sheet clip (300) has a contact sheet clip back (301) and two contact sheet clip legs (302) which extend from the contact sheet clip back, wherein each of the two contact sheet clip legs (302) has a main extension plane (302a) and a plurality of, in particular elastic, contact sheets (303) which protrude from the main extension plane, wherein the contact sheets (303) of the two contact sheet clip legs (302) protrude outward, wherein one of the two contact sheet clip legs (302) is fastened on each of the two plug-in section contact surfaces (201).

Description

Technical Field

[0001] The present invention relates to contact elements, plug connectors having such contact elements, and plug connector arrangement structures having such plug connectors. Background Technology

[0002] In automobile manufacturing, due to ease of assembly and maintenance, components of alternative drive units are increasingly being designed with plug-in connections in terms of their electrical contacts. This places the highest demands on plug-in connections regarding electrical contact characteristics, load capacity, sealing, and structural space.

[0003] WO 2005 / 096448 A1 discloses an electrical socket contact for high-current applications, comprising a plug receiving portion configured according to a type of cage for receiving complementary plug contacts, the plug receiving portion having two side members facing each other with respect to the plug receiving portion, and the plug receiving portion including a contact sheet insert disposed within the plug receiving portion, the contact sheet insert having at least one base extending parallel to the side members, and having a plurality of contact sheets coupled to the base and protruding from the plane of the base with their contact areas, wherein the contact sheets are configured as protrusions coupled unilaterally to the base of the contact sheet insert and having their contact areas in the region of their free ends. Summary of the Invention

[0004] According to the present invention, contact elements having the features of the independent claims, mating connectors having such contact elements, and mating connector arrangements having such mating connectors are proposed. Advantageous designs are the subject of the dependent claims and the following description.

[0005] The present invention realizes a contact element that can be easily manufactured and, in particular, enables reproducible positioning with low tolerances in plug connectors.

[0006] The contact element has a mating section and a contact sheet clip fastened to the mating section.

[0007] The plug section is formed by deforming the ends of an electrical conductor, particularly a stranded conductor, and has two opposing, particularly far apart, and particularly flat plug section contact surfaces. The two plug section contact surfaces can extend parallel to each other, and the plug section can particularly have a cuboid shape. The electrical conductor can, for example, have a circular, elliptical, or cylindrical cross-section. The plug section can be deformed, for example, by a compaction process, such as extrusion deformation and / or deformation by means of an ultrasonic welding head (introducing ultrasonic waves). For example, by supplying heat and / or pressure, a conductor that was previously, for example, elliptical or circular, can be shaped into an angular form, wherein the individual conductor strands or strands can be fused together (cold welded) in the compacted area. The electrical conductor and the plug section are suitably made of metal, particularly copper or containing copper.

[0008] The conductors are particularly designed for high-current applications, in which a current of at least 1 A, at least 10 A, at least 50 A, or at least 100 A flows through the conductors and therefore also through the plug sections and contact elements.

[0009] The cross-section of the electrical conductor can be at least 10 mm. 2 Or 30 mm 2 Or 50 mm 2 Or 75 mm 2 The cross-section of the electrical conductor can be, for example, 35 mm. 2 Or 50 mm 2 Or 95 mm 2 .

[0010] Electrical conductors are specifically designed for so-called high-voltage applications, in which a voltage of at least 42 V, at least 60 V, at least 100 V, at least 200 V, or at least 400 V is applied.

[0011] The contact element is configured to be inserted into the connector housing of the connector along an insertion direction. The insertion direction can, for example, extend along the longitudinal axis of the contact element. The insertion direction can, for example, extend along an electrical conductor, with a mating section constructed at the end of the electrical conductor.

[0012] The insertion section can have a free end, especially the distal end. Viewed along the insertion direction, this end can be, for example, the distal end.

[0013] The contact sheet clip, also an aspect of the invention, has a contact sheet clip back and two contact sheet clip legs extending from the back of the contact sheet clip, wherein each of the two contact sheet clip legs has a main extending plane and a plurality of particularly resilient contact sheets protruding from the main extending plane. The contact sheets of the two contact sheet clip legs protrude outward. The contact sheets can, for example, be contacted by mating contact elements that surround the contact elements from the outside. One of the two contact sheet clip legs is fastened to each of the two insertion segment contact surfaces. In the fastened state, for example, the two contact sheet clip legs are opposite each other. In other words, the contact sheet clip in the fastened state is substantially U-shaped, wherein the two contact sheet clip legs extend substantially perpendicular to and parallel to each other from the back of the contact sheet clip, and wherein the contact sheets of the two contact sheet clip legs protrude outward (away from the interior space of the U-shape).

[0014] The contact elements can be advantageously and particularly easily manufactured because the contact sheet clips can be folded around the interlocking sections before the two contact sheet clip legs are fastened to the contact surfaces of the two interlocking sections. This eliminates the need for complex orientation of the two individual contact sheet elements relative to each other on the contact surfaces of the two interlocking sections before fastening, as the two contact sheet clip legs are held together by the back of the contact sheet clips and are already correctly pre-positioned relative to each other. The contact sheet clips can also be manufactured easily and cost-effectively. Compared to two individual sheet elements, inaccurate orientation before assembly at the interlocking sections can be easily avoided.

[0015] Therefore, in the design of this invention, the contact sheet clip can be constructed, for example, as a stamped and bent part. The contact sheet clip is suitably made of metal, particularly including copper alloys or copper, such as brass. The contact sheet clip can be coated with a metal layer, particularly silver or containing silver, and / or gold or containing gold, and / or tin or containing tin.

[0016] In the secured state, the contact sheets of the two contact sheet clip legs protrude outwards or point outwards, and are pointing away from each other. The direction indicator “outwards” refers to the contact element and the contact sheet clip; in contrast, the contact sheets in, for example, those in WO 2005 / 096448 A1 mentioned above, protrude inwards and point towards each other.

[0017] The plug connector according to the invention has a contact element according to the invention and a plug connector housing surrounding the contact element. The plug connector housing has at least one housing guide element that interacts with at least one clip guide element of the contact sheet clip to orient the contact element within the plug connector housing. This allows for particularly reliable and precise assembly and / or orientation and / or centering of the contact element within the plug connector housing using readily available means. The plug connector housing can be made of a heat-resistant plastic, such as, for example, polybutylene terephthalate (PBT) or polyamide (PA).

[0018] The plug connector arrangement according to the invention has a plug connector according to the invention and a mating plug connector with mating contact elements, wherein the mating contact elements have two opposing, particularly flat, particularly mutually pointing mating contact element surface sections, and the contact elements are received between the two mating contact element surface sections.

[0019] This advantageously provides a particularly compact plug-in connection, especially for high-current applications, in which individual components have high current-carrying capacity and can be easily, accurately, and cost-effectively manufactured, and can be easily and reliably plugged together. In particular, there is no need to provide an external retainer for the sheet insert, which significantly simplifies the manufacturing of the contact elements. The mating contact elements can also be easily formed, for example, from a workpiece, such as by U-bending, and then from the outside contacting the outward-pointing sheet. Additionally, this reduces the number of contact transition points, as there is only one contact transition point from the contact sheet clip to the plug section. This eliminates the need for additional transitions relative to the external retainer or the contact carrier. This advantageously reduces the thermal load, especially during long-term high-power transmission (e.g., multiple kW over several hours).

[0020] The mating contact elements are suitably made of metal, particularly copper or copper alloys, or contain copper, such as brass. The mating contact elements can be coated with a metal layer, particularly silver or containing silver, and / or gold or containing gold, and / or tin or containing tin. The mating connector also includes a mating connector housing in the design. The mating connector housing can be made of heat-resistant plastics, such as, for example, polybutylene terephthalate (PBT) or polyamide (PA).

[0021] In the design, the contact sheet clip has two bent sections, wherein the back of the contact sheet clip is connected to one of the two contact sheet clip legs via each of the two bent sections. In an exemplary design of the invention, the two bent sections can extend substantially parallel to each other. The two bent sections can, for example, laterally surround or define the back of the contact sheet clip. Specifically, the bent sections can be used to design the overall shape of the contact sheet clip in a predetermined manner and to specifically design the transition from the back of the contact sheet clip to the contact sheet clip legs, so that the contact sheet clip can be easily used as a positioning device for contact elements, such as in a plug connector housing.

[0022] Thus, the contact sheet clip can advantageously possess, or rather fulfill, multiple functions integrated into a single component (e.g., providing contact sheets for reliable, tolerance-compensated contact, easy assembly at the mating section, and easy positioning within the mating connector housing). This eliminates the need for complex separate components for these functions.

[0023] In the design, at least one of the two contact sheet clip bending sections has a profile in cross-section consisting of right-bending and left-bending contour sections. When viewed in cross-section of the contact sheet clip such that the contact sheet clip, or its U-shape, opens downwards and the back of the contact sheet clip is in a horizontal plane, the back of the contact sheet clip defines the contact sheet clip upwards, and the contact sheet clip legs extend downwards from the back and define the contact sheet clip on the right and left sides. In this view, there are contact sheet clip bending sections adjacent to each other on the right and left sides of the contact sheet clip back, wherein the left contact sheet clip bending section originates from the contact sheet clip back, first bending to the left to form a downward bend, and then bending to the right to transition from the bend to the left contact sheet clip leg. The right-side contact sheet clip bending section originates from the back of the contact sheet clip, first bending to the right to form a downward bend, and then bending to the left to transition from the bend into the right-side contact sheet clip support leg. In this view, the outline of the right-side contact sheet clip bending section resembles a question mark, and the outline of the left-side contact sheet clip bending section resembles a vertically mirrored question mark.

[0024] This allows for particularly easy assembly of the contact sheet clip at the insertion section. The two bent contact sheet sections advantageously, for example, elastically and reversibly pre-tighten the contact sheet clip inwards, allowing it to initially bend slightly when fitted onto or placed on the insertion section, and automatically press against the insertion section once the desired position is reached. The process of securing the contact sheet clip legs to the contact surface of the insertion section can be performed while stationary and without additional retaining devices or at least retaining devices of a small defined size. Furthermore, the two bent contact sheet sections advantageously ensure that the contact sheet clip legs do not bend when there are variations in the thickness or width of the insertion section (e.g., due to machining tolerances), which could result in bending forces even after securing the contact sheet clip legs to the contact surface of the insertion section. Therefore, tolerance compensation for the insertion section is easily provided in the contact sheet clip. Furthermore, the bending section advantageously reinforces the contact sheet clip. In this way, the contact sheet clip can be assembled and / or centered and / or oriented more easily and reliably at the insertion section.

[0025] In the design, a particularly minimum first gap between the outer edges of the bent sections of the contact sheet clip is greater than a particularly minimum second gap between the two main extending planes of the contact sheet clip legs. In other words, the right and left bent sections of the contact sheet clip each have outer edges, the minimum gap of which is greater than the minimum gap between the main extending planes of the two contact sheet clip legs in the fastened state. For example, the minimum first gap can be at least 5% larger than the minimum second gap, preferably at least 10% larger, and particularly preferably 15% larger. The aforementioned gaps are measured in particular parallel to the plane of the back of the contact sheet clip. Specifically, the minimum gap between the outer edges of the bent sections of the contact sheet clip corresponds to the maximum width of the contact sheet clip measured in a plane parallel to the back of the contact sheet clip.

[0026] In this way, the bent sections of the contact sheet clips advantageously ensure reliable and reproducible orientation of the contact sheet clips, and thus the contact elements, in particular the connector housing of the plug connector. Furthermore, this advantageously allows for easy compensation of thickness or width tolerances in the plug section. Since centering in the connector housing can be achieved, for example, by two bent sections of the contact sheet clips, the tolerances of these two bent sections can be controlled very accurately with respect to their initial spacing. Moreover, this width difference advantageously provides an encoding structure that allows the plug section to be inserted into the connector housing only in one direction.

[0027] In the design, one of the two contact sheet clip legs is welded to the contact surface of each of the two insertion sections.

[0028] Therefore, it is advantageous to achieve a readily manufacturable, reliable, and durable connection between the contact element and the contact sheet clip. This also results in high current carrying capacity and reduces the risk of poor contact or arcing. Finally, it advantageously creates a particularly low transition resistance between the insertion section and the contact sheet clip legs, which, for example, minimizes heat generation at the contact points when transmitting high currents, such as in electrically operated vehicles.

[0029] In the design, the insertion section is spaced apart from the back of the contact sheet clip. For example, the length of the minimum gap between the insertion section and the back of the contact sheet clip can depend on the dimension of the contact surface of the insertion section along the direction of this minimum gap. Furthermore, the longer the contact surface of the insertion section, the smaller the gap.

[0030] By presetting the spacing, the desired position of the mating section relative to the contact clip and therefore also relative to the connector housing can be advantageously achieved. Furthermore, tolerance compensation can be advantageously provided by varying the spacing relative to the height of the mating section. Even when the height of the mating section is particularly large (e.g., at the upper tolerance limit), the position of the contact clip relative to the connector housing, or rather, relative to the mating contact element, can still be achieved. In principle, the same contact clip element can also be used in this way for mating sections constructed with different heights (e.g., for different current-carrying capacities or the current or voltage to be transmitted). This advantageously facilitates the use of universal components (for the contact clip element), thereby saving costs.

[0031] In the design, at least one housing guide element has a groove, and at least one clip guide element has a contact sheet clip back, wherein the contact sheet clip back is received in the groove.

[0032] Therefore, the contact element can advantageously be oriented vertically upwards within the connector housing in an easy manner and without additional positioning elements, wherein, viewed from the cross-section of the contact sheet clip as described above, the contact sheet clip, or its U-shape, opens downwards and the back of the contact sheet clip is positioned in a horizontal plane. Advantageously, the contact clip element can perform multiple functions as an integrated single component. Thus, the contact element can be manufactured particularly easily, cost-effectively, and reliably.

[0033] For example, it can be configured such that the back of the contact sheet clip rests against the bottom of the groove or the top cover.

[0034] In the design, (at least one) clip guide element has a contact sheet clip bending section that abuts against the groove sidewall of the groove as a housing guide element.

[0035] Therefore, the contact element can be advantageously oriented laterally or horizontally within the connector housing in an easy manner and without additional positioning elements, wherein, viewed from the cross-section of the contact sheet clip as described above, the contact sheet clip, or its U-shape, opens downwards and the back of the contact sheet clip is in a horizontal plane. Advantageously, the contact clip element can perform multiple functions as an integrated single component. Thus, the contact element can be manufactured particularly easily, cost-effectively, and reliably.

[0036] In the design, (at least one) housing guide element has at least one plug connector housing abutment surface, wherein (at least one) clip guide element has a contact sheet clip leg abutment surface of at least one of two contact sheet clip legs, particularly the end face of the contact sheet clip leg, the contact sheet clip leg abutment surface particularly protruding beyond the front end of the plug section, wherein the plug connector housing abutment surface and the contact sheet clip leg abutment surface abut against each other, particularly against the front end of the contact element, such that a stop is constructed for the contact element, particularly when inserted into the plug connector housing in the insertion direction.

[0037] This advantageously results in the contact element being securely and reliably fitted into its designated position within the connector housing, always when viewed along the insertion direction. Both the contact clip and the connector housing's abutment surfaces can be manufactured with low tolerances, and the contact clip can be fitted with low tolerances relative to the insertion section. If the contact clip abutment surfaces, particularly those projecting forward (along the insertion direction) beyond the insertion section, are omitted, only the front end of the insertion section is usable along the insertion direction (acting in conjunction with the front inner wall of the connector housing). However, when the insertion section is manufactured as a compact end, this front end can be quite rough and have large tolerances regarding the foremost point. This front end can be constructed like a hardened, tangled bundle of twisted wire (appearing roughly like a bale of straw). A well-defined foremost point or foremost surface cannot be obtained without additional costly processing steps (such as cutting). The contact sheet clamp abutment surface now serves as a stop and therefore as a positioning aid, thereby advantageously eliminating the need for additional processing (smoothing steps) of the compacted end.

[0038] Advantageously, the contact sheet clip abutment surface protrudes beyond the undefined front end of the mating section. However, it is entirely conceivable that the contact sheet clip stop surface is located approximately at the height of the front end of the mating section or even retracted behind it. In such a case, for example, the mating connector housing abutment surface can be configured to be laterally guided relative to the mating section and abut against the contact sheet clip abutment surface with a lateral misalignment relative to the front end of the mating section. It can then even have the additional function of acting as a stop against lateral displacement (e.g., tipping over or pivoting).

[0039] The mating surface of the connector housing can, for example, face the contact element. The mating surface of the connector housing can, for example, be located on or constructed within the inner wall of the connector housing.

[0040] As an alternative or additional option, the connector housing can be configured to have an inwardly projecting guide tab at the front end of the connector housing, particularly against the insertion direction. The guide tab gradually narrows in width when viewed particularly against the insertion direction, wherein at least one contact sheet clip leg protrudes beyond or extends beyond the insertion section and beyond or protrudes beyond the guide tab, particularly when viewed along the insertion direction. This is done in such a way that the guide tab is configured to provide lateral guidance or lateral stop for the contact element transverse to the insertion direction.

[0041] In particular, regarding the displacement, pivoting, or overturning of the mating section inward or away from the adjacent outer wall of the mating connector housing, the guide tab can thus act as a lateral stop.

[0042] The contact sheet clip legs can, for example, protrude beyond the front end of the insertion section. Alternatively or additionally, the contact sheet clip legs can also protrude beyond the upper and / or lower ends of the insertion section (e.g., on the side of the back of the contact sheet clip, for example, located at the upper end of the insertion section; this protruding section can, for example, extend forward or backward relative to it). If pivoting now occurs, the guide tab forms a stop against the inner wall of the contact clip using its outer wall, or laterally outward-pointing surface. The inner wall of the contact clip then abuts against the guide tab and prevents further pivoting or displacement in the direction of the guide tab.

[0043] If the two contact sheet clip legs protrude beyond the ends of the insertion sections (e.g., the front and / or top and / or bottom ends of the insertion sections), then the guide tab can be positioned or captured between the protruding sections of the two contact sheet clip legs (especially when viewed transversely to the insertion direction).

[0044] Therefore, the contact element can be oriented in the connector housing about the roll angle (that is, the contact element pivots about the axis of rotation extending along the back of the contact clip or parallel to the insertion direction) and can be oriented axially (that is, along the axis of rotation), wherein, as described above, the cross-section of the contact clip is viewed such that the contact clip, or its U-shape, opens downward and the back of the contact clip is in a horizontal plane.

[0045] Here, particularly in the region where the contact sheet clip protrudes beyond the front of the insertion section, the guide tab's transverse direction pointing in the insertion direction can, for example, interact with the inner wall of the contact sheet clip. This can exemplarily be a section that also has a stop surface for the contact sheet clip. However, it is conceivable that this applies to other regions or sections of the contact sheet clip.

[0046] The selectively gradually narrowing width of the guide tab advantageously simplifies the assembly of the contact element. This is because the guide tab thus has at least one, and particularly advantageously two, guide slopes. This allows, for example, the capture of a contact element that is initially inserted at a slight tilt or pivot, in such a way that, for example, a section of the contact clip leg protruding beyond the front end of the insertion section couples with one of the guide tabs or its outer side, and then slides outward along the slope (transverse to the insertion direction).

[0047] If two functions are achieved (a forward stop by the combined action of at least one contact sheet clip leg abutment surface and at least one plug connector housing abutment surface, and a lateral stop by the combined action of the contact sheet clip inner wall and the guide tab), then it is advantageous to achieve a particularly high degree of functional integration into or by means of the contact sheet clip.

[0048] In this design, the contact sheet rests against the mating contact element surface section. This allows for a reliable electrical contact between the plug connector and the mating plug connector.

[0049] Another aspect of the invention relates to a method for manufacturing a contact element according to the invention, the method comprising fastening a contact sheet clip to a mating section as described above, the mating section being formed by deforming the ends of an electrical conductor, particularly an electrically stranded conductor, and having two opposing, particularly far apart, and particularly flat mating section contact surfaces. One of the two contact sheet clip legs is fastened, particularly welded, to each of the two mating section contact surfaces.

[0050] In the design scheme, the ends of the electrical conductors are deformed to form a splice section, particularly through a compaction method. This compaction method can, for example, include the following steps: - The ends of cables or wires, especially those with multiple strands, are introduced into a compact mold, which in particular has a welding anvil (in the lower part), two side parts, and an ultrasonic welding head (in the upper part). - Apply ultrasonic excitation to the end of a cable or wire using an ultrasonic welding head; - Especially with the help of an ultrasonic welding head, heat and / or pressure are supplied to the end of the cable or wire.

[0051] As an alternative or supplement to ultrasonic welding heads and ultrasonic excitation, it is also possible to set up so-called resistance compaction, in which the heat necessary for the compaction process is supplied by guiding current through the end of a wire or cable.

[0052] In the design, the back of the contact sheet clip and the two contact sheet clip legs are formed in a U-shape in cross-section, and / or the contact sheet clip is pushed onto the insertion section. Therefore, the contact element can be formed in an easy manner.

[0053] In the design, one of the two contact sheet clip legs presses against one of the two insertion section contact surfaces, and the contact sheet clip leg is secured at the insertion section contact surface. Therefore, the contact sheet clip can be securely and extensively, thus securing itself at the insertion section with good electrical contact. This pressing can be achieved, for example, in addition to the inward-acting spring force of the contact sheet clip.

[0054] In other words, the advantages of the aspects proposed by the present invention are as follows: By connecting two contact sheet legs to the back of the contact sheet clip, a bending-resistant area can be created through bending. This bending-resistant area serves as a guide surface and / or abutment surface and as a centering point for the contact sheet clip within the connector housing. The orientation of the contact sheet within the connector housing is of decisive importance for a functional mating connection (with mating connectors), as the contact sheet should abut evenly on both sides against the contact mating parts (mating contact surface sections).

[0055] In particular, compared to direct contact of the contact sheets on the compacted wires (compacted plug sections), the present invention offers advantages because the compacted and therefore the dimensions and surface quality of the plug sections are strongly tolerant, that is, have larger or higher tolerances than, for example, cast plug sections or the like. Due to these larger or higher tolerances, precise centering of the individual contact sheet elements (which are not connected to each other by means of the back of contact clips) in the compacted area is difficult to achieve. Even with the larger or higher tolerances of the plug sections, the contact sheet clips thus enable easy, reliable, and cost-effective manufacturing of the contact elements.

[0056] Additionally, the width of the conductor or mating section can vary according to customer requirements (e.g., regarding the current intensity, voltage, etc.). Advantageously, despite these different sizes of the mating section, the same contact clip can be used. For different conductor cross-sections, this allows for the advantageous use of the same mating connector housing, which must be adapted to the mold, for example, only through mold inserts, to take into account the conductor cross-section used.

[0057] Overall, the manufacturing of contact elements, plug connectors, and plug connector arrangements can therefore be significantly simplified, designed more cost-effectively, and implemented as a modular solution.

[0058] Further advantages and design solutions of the present invention are available from the specification and drawings.

[0059] The present invention is illustrated schematically with reference to the embodiments in the accompanying drawings, and will now be described with reference to the drawings. Attached Figure Description

[0060] Figure 1 An embodiment of the contact element is shown, viewed from the front at an angle in a perspective view.

[0061] Figure 2 This shows a perspective view taken from the side at an angle. Figure 1 Implementation of contact elements.

[0062] Figure 3 An embodiment of the contact element as viewed from above is shown.

[0063] Figure 4 An embodiment of the contact element as viewed from below is shown.

[0064] Figure 5 An embodiment of the contact element as viewed from the side is shown.

[0065] Figure 6An enlarged section of the contact element is shown in a cross-sectional view, in which the curved section on the back of the contact element clip is particularly visible.

[0066] Figure 7 An embodiment of a plug connector with contact elements and a plug connector housing is shown in a cut-out side view.

[0067] Figure 8 A cut-off portion of a cross-sectional view of the plug connector as seen from the front is shown.

[0068] Figure 9 shows a cross-sectional view of a first embodiment of the plug connector in view a), and a cross-sectional view of a second embodiment of the plug connector in view b).

[0069] Figure 10 The perspective view shows the arrangement of... Figure 6 The plug connector arrangement structure is a part of the plug connector and mating plug connector. Detailed Implementation

[0070] refer to Figures 1 to 6 The preferred embodiments of the contact element 100 according to the present invention will now be described coherently and comprehensively. Furthermore, refer to... Figure 7 A preferred embodiment of the plug connector 10 according to the invention, having contact element 100 and plug connector housing 20, is described coherently and comprehensively up to FIG9. Figure 10 The perspective view shows a plug connector arrangement structure 1 having a plug connector 10 and a portion of a mating plug connector.

[0071] The contact element 100 has a mating section 200 and a contact sheet clip 300 fastened to the mating section 200. The mating section 200 is formed by deforming the wire end 210 of the electrical conductor 220, which exemplarily relates to the compaction or compacted end of the conductor. The mating section 200 has two opposing mating section contact surfaces 201. The two mating section contact surfaces 201 are constructed flat and are directed outwards and away from each other. A (Cartesian) coordinate system (with x-direction x, y-direction y, and z-direction z) is shown in the figure, in which the mating section contact surfaces 201 lie in the yz plane.

[0072] The conductor 220 can be an extruded, ultrasonically welded, or resistance-compacted stranded conductor. This deformation method can be referred to as compaction. The conductor 220 and the insertion section 200 are, for example (especially the main part) made of copper, copper alloy, or the like, or constructed thereof, and the contact clip 300 can also be, for example, made of copper or copper alloy, or constructed thereof. In other cases, the conductor 220 can be made of aluminum (especially the main part), aluminum alloy, or the like.

[0073] The contact sheet clip 300 has a contact sheet clip back 301 and two contact sheet clip legs 302 extending from or protruding from the contact sheet clip back.

[0074] Contact element 100 can be configured to be inserted into the connector housing 20 of the connector 10 along the insertion direction E (which is exemplarily opposite to the y-direction y-extension) (see, for example, [link to relevant documentation]). Figures 7 to 10 The insertion direction E can extend, for example, along the longitudinal axis of the contact element 100. The insertion direction can extend, for example, along the electrical conductor 220, with the insertion section 200 constructed at the end of the electrical conductor.

[0075] The plug section 200 can have a free end. Viewed along the insertion direction E, this end can be, for example, the distal end. The free end can be the front plug section end 27. For example, due to a compaction process, the free end of the plug section 200 can be constructed roughly, or rather, messily, or rather, strongly modified, or not have a smooth surface. Individual strands that have been crimped, cold-welded, or deformed together during this process can, for example, still protrude individually from the front plug section end 27. This is, for example, in... Figure 1 , 2 As shown in 10.

[0076] The front plug section end 27 is located in the region of the front contact element end 24. In the rear contact element end 25, the plug section 200 serves in particular as a compacted end of the conductor 220, which here exemplarily transitions to (non-compacted) electrical conductor 220.

[0077] Each of the two contact sheet clip legs 302 has a main extending plane 302a and a plurality of particularly resilient contact sheets 303 protruding from the main extending plane. As shown in the figure, the contact sheets 303 of the two contact sheet clip legs 302 protrude outward and point away from each other.

[0078] The two contact sheet clip legs 302 each have a contact sheet clip inner wall 28, which faces the insertion section 200.

[0079] In the figure, the main extension plane 302a is also located in the yz plane, and the contact sheet 303 protrudes in the x-direction or in the opposite direction to the x-direction. The back of the contact sheet clip 301 is exemplarily located in the xy plane here.

[0080] One of the two contact sheet clip legs 302 is fastened, and in particular welded, to the inner wall 28 of the contact sheet clip on each of the two plug-in segment contact surfaces 201, thereby resulting in low transition resistance.

[0081] Furthermore, the contact sheet clip 300 has two contact sheet clip bending sections 304, wherein each contact sheet clip back 301 is connected to one of the two contact sheet clip legs 302 via one of the two contact sheet clip bending sections 304. Specifically, the two contact sheet clip bending sections 304 extend substantially parallel along the y-direction and laterally surround the contact sheet clip back 301, that is, they restrict the contact sheet clip back 301 along the x-direction.

[0082] For example, by Figure 6 As well as it was derived, in Figure 6 The image shows an enlarged cross-section of the right-hand contact sheet clip bending section 304, which has a right-bending profile section 304a followed by a left-bending profile section 304b. This results in a profile that approximates a question mark shape. The left-hand contact sheet clip bending section 304 is constructed in a mirror image.

[0083] The outermost edge of the bent section 304 of the contact sheet clip is denoted by 304c, wherein the particularly minimal first gap D1 between the two outer edges 304c (left and right) is greater than the particularly minimal second gap D2 in the x-direction between the two main extension planes 302a of the contact sheet clip leg 302 (see...). Figure 2 , 3 8, 9a, 9b).

[0084] Especially as by Figure 8Or as shown in views a) and b) of Figure 9, which respectively show cut-off portions of cross-sectional views of the plug connector 10 according to an embodiment of the invention, one of the two contact sheet clip legs 302 is fastened to each of the two plug segment contact surfaces 201, such that in the fastened state, the two contact sheet clip legs 302 are opposite each other. In other words, the contact sheet clip 300 in the fastened state is substantially U-shaped, wherein the two contact sheet clip legs 302 extend substantially perpendicular to and parallel to each other from the back of the contact sheet clip 301. Figure 8 , 9a And in 9b, downwards or towards the z-direction.

[0085] Furthermore, it can be seen that the back 301 of the contact sheet clip can be spaced apart from the insertion section 200 (here: parallel to the z-direction z), in Figure 9a A first back spacing d1 is separated in the middle, wherein the insertion section 200 has a first height X1 parallel to the z-direction, and... Figure 9b A second back spacing d2 is separated in the middle, wherein the insertion section 200 has a second height X2 parallel to the z-direction. In both cases, the insertion section 200 has a width along the x-direction of the second spacing D2, which is only slightly smaller than the second spacing between the main extension planes 302a of the contact sheet clip legs 302 (which is essentially caused by the (twice) material thickness of the contact sheet clip 300).

[0086] In addition Figure 8 , Figure 9a , 9b The diagram shows a cut-off portion of a plug connector housing 20 according to an embodiment of the plug connector 10 of the present invention. The plug connector housing 20 has a recess 21 with a recessed bottom 21a and recessed sidewalls 21b, a contact sheet clip back 301 abutting the bottom of the recess, and a contact sheet clip bent section 304 abutting the sidewalls of the recess. In this sense, the recess 21 acts as a housing guide element that interacts with the contact sheet clip back 301, which acts as a clip guide element. Therefore, the contact element 100 can be oriented vertically upward (towards the z-direction) and horizontally (towards the x and x-directions) within the plug connector housing 20. The directional indications "up" and "down" refer to the orientation shown, in which the contact sheet clip back 301 is horizontally located in the xy-plane and the contact sheet clip legs protrude in the z-direction (i.e., downward).

[0087] The bottom 21a of the groove forms a housing guide element that interacts with the back 301 of the contact sheet clip, which serves as a clip guide element. Therefore, the contact element 100 can be oriented vertically upwards within the connector housing 20. Similarly, the sidewall 21b of the groove forms a housing guide element that interacts with the bent section 304 of the contact sheet clip, which also serves as a clip guide element. Therefore, the contact element 100 can be oriented laterally or horizontally within the connector housing 20.

[0088] For example, by Figure 7 As it turns out, this housing guide element, or rather these housing guide elements, also have a plug connector housing abutment surface 22 (here, for example, on the plug connector housing 20 facing the contact element 100). Figure 7 (At the front inner end shown on the left). Furthermore, this clip guide element, or rather these clip guide elements, have a contact sheet clip leg abutment surface 305 (contact sheet clip 300 or two contact sheet clip legs 302 at the...). Figure 7 At the outer distal end shown on the left, the contact sheet clip leg here only exemplarily protrudes beyond the front insertion section end 27, wherein the insertion connector housing abutment surface 22 and the contact sheet clip leg abutment surface 305 abut against each other (they abut against each other when viewed along the insertion direction E), especially at the front end 24 of the contact element 100, such that a stop is constructed for the contact element 100 when inserted into the insertion connector housing 20, especially along the insertion direction E, or in other words, the stop is constructed in the insertion state.

[0089] Figure 7 Furthermore, it is shown that a guide tab 23 is arranged at the front end of the connector housing 20, particularly on the inner side of the connector housing 20 facing the contact element 100. The guide tab 23 here, exemplarily, protrudes slightly from the connector housing abutment surface 22 in the direction of the contact element 100 (towards the y-direction y, or in contrast to the insertion direction E), or in other words, the guide tab protrudes inward or backward in contrast to the insertion direction. In the x-direction x, which extends perpendicular to the y-direction y, the front inner end of the connector housing 20 protrudes slightly beyond the guide tab 23. The connector housing abutment surface 22 is formed on both sides of the guide tab 23, exemplarily creating a T-shape.

[0090] At least one contact sheet clip leg 302 (here: two contact sheet clip legs 302), which, by way of example only along the insertion direction E, protrudes beyond the insertion section 200 and extends beyond the guide tab 23, in particular, such that the guide tab 23 constitutes a lateral stop for the contact element 100 transverse to the insertion direction E.

[0091] In other words: the contact sheet clamp leg abutment surface 305 bridging the guide tab 23 along the insertion direction E, or protruding beyond the guide tab.

[0092] In this way, the guide tab 23 causes the contact element 100 to be guided in the x-direction x. Viewed in the x-direction x, the guide tab 23 is located between the abutment surfaces 305 of the two contact sheet clip legs, or between the inner walls 28 of the two contact sheet clip legs 302 that point towards each other radially inward (parallel to the x-direction x).

[0093] For example, the guide tab 23 can be configured to extend obliquely to its outward-pointing side (e.g., the width of the guide tab 23 gradually decreases against the insertion direction E). In this way, the guide tab constitutes an inlet tilt for the front end of the contact sheet clip leg 302. This ensures that the contact element 100 is assembled particularly easily, reliably, and securely within the plug connector housing 20. Through the inlet tilt, the contact element 100, which may initially be easily tipped over or pivotally inserted, automatically pivots to the correct position about the rotation axis already described above.

[0094] exist Figure 10 The diagram shows a cutaway representation of an embodiment of a plug connector arrangement 1 according to the invention, the plug connector arrangement having a plug connector 10 including a contact element 100 and a mating plug connector with mating contact elements 2 (here only shown as a portion of the mating plug connector). The mating contact elements 2 again have two opposing mating contact element surface sections 2a, which in the illustrated embodiment are constructed particularly flat or planar and point towards each other (inwards). The contact element 100 is received between the two mating contact element surface sections 2a to close the plug connector arrangement 1, wherein the contact sheet 303 of the contact element 100 abuts against the (inwardly facing) mating contact surface section 2a.

[0095] In order to manufacture the contact element 100, as described hereafter, the contact sheet clip 300, which can be configured as a stamped bending piece and / or has a good conductive material such as copper, copper alloy or the like or other metals, is first bent into a U-shape, wherein the transition from the back of the contact sheet clip 301 to the contact sheet clip leg 302 is constructed by means of the contact sheet clip bending section 304 as described above.

[0096] Such a contact clip 300 is then placed or pushed onto the insertion section 200, which is formed by deforming (compacting, configured as a compacted end) the wire end 210 of the electrical conductor 220, particularly the stranded conductor, and has two opposing, particularly far apart, and particularly flat or planar insertion section contact surfaces 201. Such pushing can be achieved, for example, parallel to the z-direction, y-direction, or a combination thereof. The insertion section 200 can be, by way of example, made of copper or other metals or materials with high electrical conductivity, such as superconductors, or have such metals, especially for the main part.

[0097] Furthermore, the contact sheet clip legs 302 are pressed against the contact surface 201 of the insertion section (wherein this can be achieved by the intrinsic spring force of the contact sheet clip 300, or such intrinsic, inwardly pointing spring force supports the pressing), and secured therein. For this purpose, the method can include: pressing one of each of the two contact sheet clip legs 302 against one of each of the two insertion section contact surfaces 201, particularly to create a planar and flush contact, and simultaneously securing the contact sheet clip legs 302 to the insertion section contact surface 201, particularly by welding.

[0098] In particular, one of the two contact sheet clip legs 302 is fastened, especially welded, to each of the two insertion section contact surfaces 201.

[0099] Furthermore, the method may also include deforming the conductor end 210 of the conductor 220 to form a plug section 200, as described above.

[0100] The aforementioned modifications can in particular include steps of a compaction method, such as introducing, for example, the conductor end 210 of the conductor 220, particularly having multiple strands, into a compaction mold, particularly having a welding anvil (in the lower portion), two side components, and an ultrasonic welding head (in the upper portion), by means of the ultrasonic welding head, applying ultrasonic excitation to the conductor end 210, and supplying heat and / or pressure to the conductor end 210, particularly by means of the ultrasonic welding head.

[0101] As an alternative or supplement to ultrasonic welding heads and ultrasonic excitation, it is also possible to set up so-called resistance compaction, in which the heat necessary for the compaction process is supplied by a guiding current through the wire end 210.

Claims

1. A contact element (100) having: - A plug section (200), which is formed by deforming the wire end (210) of an electrical conductor (220), particularly an electrically stranded conductor, and has two opposing, particularly far apart, and particularly flat plug section contact surfaces (201), and - A contact sheet clip (300) fastened at the insertion section (200). in, The contact sheet clip (300) has a contact sheet clip back (301) and two contact sheet clip legs (302) extending from the contact sheet clip back. Each of the two contact sheet clip legs (302) has a main extension plane (302a) and a plurality of particularly resilient contact sheets (303) protruding from the main extension plane. Among them, the contact sheets (303) of the two contact sheet clamp legs (302) protrude outward. One of the two contact sheet clip legs (302) is fastened to each of the two insertion section contact surfaces (201).

2. The contact element (100) according to claim 1. in, The contact sheet clip (300) has two contact sheet clip bending sections (304). The back of the contact sheet clip (301) is connected to one of the two contact sheet clip legs (302) via one of the two contact sheet clip bending sections (304). In particular, the two contact sheet clip bending sections (304) extend substantially parallel to each other and laterally surround the back of the contact sheet clip (301).

3. The contact element (100) according to claim 2. in, At least one of the two contact sheet clip bending sections (304) has a profile in cross-section consisting of right-bending and left-bending profile sections (304a, 304b).

4. The contact element (100) according to claim 2 or 3. in, The particularly smallest first gap (D1) between the outer edges (304c) of the bent section (304) of the contact sheet clip is greater than the particularly smallest second gap (D2) between the two main extension planes (302a) of the contact sheet clip leg (302).

5. The contact element (100) according to any one of the preceding claims. in, One of the two contact sheet clip legs (302) is welded to each of the two insertion section contact surfaces (201).

6. The contact element (100) according to any one of the preceding claims. in, The insertion section (200) is spaced apart from the back of the contact sheet clip (301).

7. A plug connector (10) having - Contact element (100) according to any one of the preceding claims. - A plug connector housing (20) surrounds the contact element (100) and has a housing guide element that interacts with a clip guide element of the contact sheet clip (300) to orient the contact element (100) within the plug connector housing (20).

8. The plug connector (10) according to claim 7. in, The housing guide element has a groove (21), and the clip guide element has the back of the contact sheet clip (301). The back of the contact sheet clip (301) is received in the groove (21).

9. The plug connector (10) according to claim 7 or 8, in cases where at least claim 3 is invoked. in, The clip guide element has a contact sheet clip bending section (304), and the housing guide element has a groove sidewall (21b) of the groove (21), wherein the contact sheet clip bending section (304) abuts against the groove sidewall (21b) of the groove (21).

10. The plug connector (10) according to any one of claims 7 to 9. in, The housing guide element has a plug-in connector housing abutment surface (22). The clip guide element has a contact sheet clip abutment surface (305) on the end face of one of the two contact sheet clip legs (302), the contact sheet clip abutment surface protruding particularly beyond the front insertion section end (27). The connector housing abutment surface (22) and the contact sheet clip leg abutment surface (305) abut against each other, particularly against the front end (24) of the contact element (100), thereby providing a stop for the contact element (100) especially when inserted into the connector housing (20) in the insertion direction (E). And / or The connector housing (20) has an inwardly projecting guide tab (23) at the front end (26) of the connector housing, particularly against the insertion direction (E). The guide tab gradually narrows in width when viewed particularly against the insertion direction (E). At least one contact sheet clip leg (302) protrudes beyond the insertion section (200) and extends beyond the guide tab (23) in particular along the insertion direction (E), such that the guide tab (23) forms a lateral stop for the contact element (100) in the insertion direction (E).

11. Plug-in connector arrangement structure (1), which has - The plug connector (10) according to any one of claims 7 to 10. - A mating plug connector with mating contact elements (2), in, The mating contact element (2) has two opposing, particularly flat, and particularly mutually pointing mating contact element surface sections (2a). The contact element (100) is received between the two mating contact element surface sections (2a).

12. The plug connector arrangement structure (1) according to claim 11. in, The contact sheet (303) abuts against the mating contact element surface section (2a).

13. A contact sheet clip (300) having a contact sheet clip back (301) and two contact sheet clip legs (302) extending from the contact sheet clip back. in, Each of the two contact sheet clip legs (302) has a main extension plane (302a) and a plurality of particularly resilient contact sheets (303) protruding from the main extension plane. When the back of the contact sheet clip (301) and the two contact sheet clip legs (302) are formed in a U-shape in cross-section, the contact sheet (303) of the two contact sheet clip legs (302) protrudes outward.

14. A method for manufacturing a contact element (100) according to any one of claims 1 to 7, the method comprising: The contact sheet clip (300) according to claim 13 is fastened to the insertion section (200), which is formed by deforming the wire end (210) of the electrical conductor (220), especially the electrically stranded conductor, and has two opposing, especially far apart, and especially flat insertion section contact surfaces (201). One of the two contact sheet clip legs (302) is fastened, and in particular welded, to each of the two insertion section contact surfaces (201).

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