A welding cup for stamped contacts

Abstract

The electrical contact includes: a first end; a second end; and a solder cup portion formed at the first end. The solder cup portion is electrically connected to an electrical component, including a wire, by welding. The solder cup portion has a circumferential wall region having an upper edge defining a solder cup opening at the first end and a solder cup base disposed opposite the solder cup opening and defining a base for the solder cup portion. The electrical contact is formed by stamping from a sheet metal.

Description

Technical Field

[0001] The present invention relates to an electrical contact having a first end and a second end, a system comprising a plurality of such electrical contacts, and a method for manufacturing the electrical contact. Background Technology

[0002] Electrical contacts are widely used to connect electrical appliances. In many cases, one or more electrical contacts are fixed or embedded in a contact holder, which is usually made of insulating material.

[0003] Typically, the "convex" and "concave" geometries of one end of a contact, especially the pin and socket geometries, are used to provide corresponding contacts that can be (temporarily) connected to each other. Typically, the end opposite the convex / concave shape has a conductive connection to electrical components, particularly one or more wires.

[0004] There are different methods for connecting electrical contacts with wires. For example, crimping can be an efficient and quick method to connect electrical contacts to one or more wires. Soldering can also be used.

[0005] Furthermore, electrical contacts can be manufactured in different ways to achieve different contact characteristics and provide suitable contacts for different applications.

[0006] For example, machined contacts and stamped contacts with crimped connections are known. Machined contacts are made from conductive metal rods that are machined to the desired geometry to produce the part. Furthermore, stamped contacts are known; they are created by stamping and shaping a contact into the desired geometry using a flat plate of conductive material. Typically, stamped contacts have portions for crimping and thus connecting to wires. Flat metal materials are particularly suitable for this type of connection.

[0007] For some applications, soldering is preferable to connecting wires to the contacts. In such applications, machined contacts are typically used. However, machined contacts are more expensive and slower to produce than stamped contacts. Summary of the Invention

[0008] In one embodiment, the present invention provides an electrical contact comprising: a first end; a second end; and a solder cup portion formed at the first end, the solder cup portion being configured to be electrically connected to an electrical component including a wire by soldering, wherein the solder cup portion includes a circumferential wall region, the upper edge of the circumferential wall region defining a solder cup opening at the first end, and a solder cup base disposed opposite the solder cup opening and defining a base of the solder cup portion, wherein the electrical contact is formed by stamping a sheet of metal. Attached Figure Description

[0009] The invention will now be described in more detail with reference to the exemplary accompanying drawings. The invention is not limited to exemplary embodiments. Other features and advantages of various embodiments of the invention will become apparent from the following detailed description, which illustrates the following:

[0010] Figure 1 Perspective views of the first and second embodiments from the first side are shown;

[0011] Figure 2 A perspective view of the first and second embodiments from the second side is shown;

[0012] Figure 3 First and second embodiments of a system with electrical contacts are shown; and

[0013] Figure 4 An embodiment of a method for manufacturing electrical contacts is shown. Detailed Implementation

[0014] In one embodiment, the invention provides a cost-effective and easy-to-use electrical contact. In particular, the electrical contact should be reliably and efficiently connected to electrical components and wires by soldering. Furthermore, an electrical contact that allows insertion of a contact holder before connection to the wire should be provided.

[0015] In one embodiment, the present invention advantageously provides an improved electrical contact, a system and method for manufacturing electrical contacts, particularly in terms of manufacturing cost, robust connection and ease of use.

[0016] This problem is addressed through electrical contacts, systems, and methods as described in this article.

[0017] In one embodiment, the present invention relates to an electrical contact having a first end and a second end. A solder cup portion is formed at the first end and configured to be electrically connected to an electrical component, particularly to a wire, by soldering. Furthermore, the solder cup portion includes a circumferential wall region and a solder cup base, the circumferential wall region having an upper edge defining a solder cup opening at the first end of the electrical contact, and the solder cup base being disposed opposite the solder cup opening and defining a base for the solder cup portion. Additionally, the electrical contact is formed by stamping from a sheet metal.

[0018] A basic idea of ​​the present invention is to provide an electrical contact with a solder cup design for connecting wires, said electrical contact being manufactured by stamping and forming a metal sheet.

[0019] Since the cost per part of stamped and formed components is much lower than that of machined contacts, the electrical contacts of the present invention can be produced very economically and efficiently. Furthermore, machining electrical contacts results in the removal of a large amount of material, leading to waste. On the other hand, stamped contacts can be produced with significantly less waste.

[0020] Furthermore, an advantage of this invention is that the electrical contacts can be inserted into the contact holder before being connected to the wire. In most cases, crimp contacts cannot be used because the close spacing of the contacts in the contact holder does not allow for crimping after insertion. On the other hand, it is difficult to insert contacts already connected to wires into the contact holder because the wires may obstruct the insertion operation and cause difficulties. These difficulties in the assembly process lead to increased labor costs per unit produced. Therefore, when using electrical contacts, this invention requires a favorable low workload.

[0021] The welding cup portion can be configured to contain welding material and coil up wire, heat to melt the welding material, and cool to harden the welding material. Thus, a permanent conductive connection is formed between the electrical contact material, the welding material, and the wire or another electrical component.

[0022] In addition, the welding cup base provides a stop for the wires or conductors of the electrical components introduced into the welding cup. Therefore, the welding process can be performed in a highly defined manner.

[0023] Specifically, the solder cup opening is configured to introduce soldering material and wire into a volume defined by the solder cup base, peripheral wall, and solder cup opening. The solder cup opening can be circular or substantially circular; its shape can also be such that its upper edge substantially defines a defining circle in a plane perpendicular to the longitudinal axis of the electrical contact, or the upper edge of the opening can have a different shape.

[0024] The electrical contact may have a convex or concave geometry at the second end, which is opposite to the solder cup portion at the first end. Furthermore, convex and concave contact geometries are known and can be used in the electrical contacts of the present invention.

[0025] The electrical contacts on the solder cup base can be formed from a generally circular sheet, which is stamped out of a metal plate and bent toward the longitudinal axis of the electrical contacts and the opening of the solder cup.

[0026] The solder cup base may have a drain port. For example, the drain port may be substantially located in the middle of the solder cup base. Specifically, the drain port is configured to provide a discharge outlet for the plating solution when the electrical contacts are immersed in the plating solution during the electroplating process. Therefore, excessive plating solution is avoided during the electroplating process.

[0027] Furthermore, inspection ports can be provided in the peripheral wall of the welding cup portion. Specifically, the inspection ports are configured to allow inspection of the level or amount of welding material and the distribution within the welding cup portion. In particular, the inspection ports can be formed between adjacent longitudinal edges of a metal plate, from which electrical contacts are formed. For example, the inspection ports can be formed by grooves in opposite edges of a flat metal sheet blank; these grooves form the inspection ports after the electrical contacts are formed. Additionally, the inspection ports can be located on one side of the electrical contacts, particularly opposite to an opening formed by a stamped circular sheet, which is subsequently bent to form the welding cup base.

[0028] The electrical contacts can be made of, for example, bronze or bronze materials. Other metals and metal alloys, as well as composite materials, can also be used. Optionally, the electrical contacts may have nickel, tin, and / or gold plating. Other suitable electroplating methods and / or treatments may be added to or used as alternatives to the application.

[0029] In addition, the electrical contact may include a baffle. The baffle may be disposed between the base of the welding cup portion and the second end of the electrical contact. Specifically, the baffle is stamped from a metal sheet and bent toward the longitudinal axis of the electrical contact, similar to the sheet forming the welding cup base. The baffle may be configured to retain welding material and / or other materials and prevent them from approaching the second end of the electrical contact. Furthermore, the baffle may be configured to limit the maximum depth of engagement between the convex and concave connection geometries.

[0030] Another aspect of the invention relates to a system comprising a plurality of electrical contacts according to the invention. The electrical contacts are embedded or inserted into a contact holder, wherein the contact holder comprises an electrically insulating material. For example, the contact holder may be formed of or comprise an insulating plastic material, into which the electrical contacts are inserted. The system can be configured such that the electrical contacts can be inserted into the contact holder prior to providing a conductive connection to a wire or electrical component via soldering.

[0031] Another aspect of the invention relates to a method for manufacturing electrical contacts according to the invention. A conductive metal plate is provided, and the electrical contacts are stamped and formed from the conductive metal plate. The solder cup portion is obtained by bending it into a circular shape along the longitudinal axis of the electrical contact. Optionally, a plating layer is applied to the electrical contacts.

[0032] Specifically, the method is used to operate an ultrasound system. Therefore, it has the same advantages as the ultrasound system of the present invention.

[0033] The following figures illustrate preferred embodiments of the invention. These embodiments should not be construed as limiting, but are merely intended to enhance the understanding of the invention in conjunction with the following description. In these figures, the same reference numerals refer to features having the same or equivalent function and / or structure throughout the drawing.

[0034] While similar and / or corresponding features are described for multiple embodiments, this does not mean that these features must be configured equally.

[0035] exist Figure 1 The image shows a first embodiment of an electrical contact 10 with a concave geometry and a second embodiment of an electrical contact 20 with a convex geometry.

[0036] Both electrical contacts 10 and 20 are shown with connected tabs 19 and 29, which are the remainder of a metal plate from which the contacts 10 and 20 are stamped. For example, when the contacts 10 and 20 are mounted in a contact holder, these tabs 19 and 29 are removed.

[0037] The two electrical contacts 10 and 20 are typically tubular and have a longitudinal axis LA.

[0038] The electrical contact 10 with a concave structure includes a first end 11 and a second end 12. A concave mating geometry 18 is arranged at the second end 12.

[0039] Similarly, the electrical contact 20 with a convex geometry also has a first end 21 and a second end 22. At the second end 22, a convex mating geometry 28 is arranged.

[0040] The configuration of the concave mating geometry 18 and the convex mating geometry 28 enables the provision of corresponding electrical contacts 10, 20, i.e., the mating geometries 18, 28 can be reversibly connected to each other, particularly by inserting the plug-like structure of the convex mating geometry 28 into the socket-like structure of the concave mating geometry 18, wherein the concave mating geometry 18 is configured to provide clamping force or other retaining force, thereby holding the convex mating geometry 28.

[0041] Solder cup portions 13 and 23 are provided at the first ends 11 and 21 of each electrical contact 10 and 20.

[0042] In these embodiments, the solder cup portions 13, 23 define a volume defined by the solder cup openings 11, 21 at the first ends 11, 21, the peripheral walls of the electrical contacts 10, 20 within the region of the solder cup portions 13, 23, and the solder cup base. In embodiments 10, 20, the solder cup base is formed of circular pieces 14, 24, which are formed from stamped portions of the electrical contacts 10, 20 and bent toward the longitudinal axis LA of the electrical contacts 10, 20. Therefore, the circular pieces 14, 24 are bent toward the inner side of the tubular electrical contacts 10, 20.

[0043] In these embodiments, the circular pieces 14, 24 are bent to extend substantially in a plane perpendicular to the longitudinal axis LA and form the bottom portions of the solder cup portions 13, 23.

[0044] The dimensions of the circular pieces 14 and 24 are such that their outer edges are substantially adjacent to the inner surfaces of the electrical contacts 10 and 20 at the bottom of the solder cup portions 13 and 23.

[0045] Since the pieces 14 and 24 are stamped from the metal plate material that forms the sidewalls of the electrical contacts 10 and 20 and bent toward the longitudinal axis LA, openings with the shape of pieces 14 and 24 are formed in the electrical contacts 10 and 20 below the solder cup portions 13 and 23, that is, between the solder cup portions 13 and 23 and the second ends 12 and 22.

[0046] Furthermore, in this embodiment, a discharge port is formed in the circular plates 14, 24. Here, the discharge port is arranged in the middle of the circular plates 14, 24, and its size is chosen such that the discharge port extends to about 10% to 50% of the area of ​​the circular plates 14, 24, preferably between 20% and 40%. The discharge port is configured to allow liquid contained within the volume of the solder cup portions 13, 23 to be discharged, especially the electroplating solution during the electroplating process.

[0047] In other embodiments not shown here, particularly when the plates 14, 24 do not have a volume that tightly closes the welding cup, the circular plates 14, 24 may be formed without a discharge port. Furthermore, the discharge port may have different forms and arrangements. Additionally, suitable discharge ports may be provided in the sidewalls of the electrical contacts 10, 20.

[0048] Furthermore, baffles 17 and 27 are stamped from the metal sheet material of the electrical contacts 10 and 20 at positions between the solder cup portions 13 and 23 and the second ends 12 and 22. In the embodiment, the baffles 17 and 27 are configured and formed in a manner similar to the circular pieces 14 and 24 forming the solder cup bases 14 and 24. Therefore, the baffles 17 and 27 are bent toward the longitudinal axis LA, and thus are arranged substantially in a plane perpendicular to the longitudinal axis LA.

[0049] In these embodiments, the openings of the baffles 17 and 27, which are stamped from sheet metal, are arranged below the positions of the baffles 17 and 27, that is, between the baffles 17 and 27 and the second ends 12 and 22.

[0050] exist Figure 2 In the images, the first 10 and the second embodiment of the electrical contact 20 are shown from substantially opposite sides.

[0051] From this perspective, connectors 10a and 20a extend along the surfaces of electrical contacts 10 and 20 and are parallel to the longitudinal axis LA. This is because electrical contacts 10 and 20 are formed by stamping from a metal sheet. At connectors 10a and 20a, the stamped edges come into contact with each other during the forming process.

[0052] Electrical contacts 10 and 20 each have an inspection port 15 and 25, which are located at the welding cup portions 13 and 23, that is, between the welding cup base 14 and 24 and the first ends 11 and 21.

[0053] In the embodiment, the inspection ports 15 and 25 are circular and consist of two symmetrical halves, respectively located on each side of the connectors 10a and 20a.

[0054] In a further embodiment, the inspection ports 15, 25 may be configured differently, for example, having a rectangular or rectangular shape and / or not provided at the connectors 10a, 20a.

[0055] The inspection port is designed to allow inspection of the arrangement of welding materials and / or wires or electrical components within the volume of the welding cup portions 13, 23. Furthermore, the welding results can be inspected, for example, to verify the required distribution of welding materials.

[0056] Furthermore, the electrical contacts 10 and 20 in both embodiments are equipped with retaining barbs 16 and 26, which are arranged and configured similarly to the inspection ports 15 and 25 at the connectors 10a and 20a. The retaining barbs 16 and 26 are configured to allow interlocking interaction between the electrical contacts 10 and 20 and the contact support when the electrical contacts 10 and 20 are inserted into the opening of the contact support, thereby biting into the support material.

[0057] For this purpose, the retaining hooks 16 and 26 may have tips or spikes that protrude outwards, i.e. away from the longitudinal axis LA of the electrical contacts 10 and 20.

[0058] In both embodiments, the electrical contacts 10, 20 are made of bronze and plated with a coating comprising nickel, tin, and / or gold. Other suitable electroplating methods and / or treatments may be added to or used alternatively.

[0059] Go to Figure 3 The first and second embodiments of systems 31 and 32 are described, the systems including contact supports 31a and 32a and a plurality of electrical contacts 31b and 32b.

[0060] Each contact holder 31a, 32a is made of insulating plastic or polymer material. Electrical contacts 31b, 32b are inserted into the openings of contact holders 31a, 32a.

[0061] Here, electrical contacts 31b and 32b essentially correspond to the contacts mentioned above. They are formed by stamping metal sheets.

[0062] Specifically, electrical contacts 31b and 32b have concave (31b) and convex (32b) mating geometries, respectively. Therefore, systems 31 and 32 are configured to complement each other, and they can temporarily connect to each other as plugs.

[0063] Furthermore, systems 31 and 32 are configured such that electrical contacts 31b and 32b are inserted without being connected to wires or other electrical components. Instead, the connection is formed later by welding. Therefore, the material selection for system contact supports 31a and 32a should ensure that it can withstand the temperatures experienced during welding, at least in the area around the welding cups of electrical contacts 31b and 32b.

[0064] Go to Figure 4 An embodiment of the method for manufacturing electrical contacts according to the present invention is described.

[0065] In the first step S1, a metal sheet is provided and a flat blank is stamped. The blank is formed and shaped so that electrical contacts are obtained by forming the blank in the second step S2.

[0066] Specifically, a circular sheet is stamped out and bent toward the longitudinal axis of the electrical contact, thereby defining the solder cup base of the solder cup portion at the first end of the resulting electrical contact.

[0067] In the third step S3, a plating layer is applied to the surface of the electrical contacts. This is done by immersing the electrical contacts in an electroplating solution, for example, by electroplating, and then removing them from the solution. To allow the electroplating solution to drain from the electrical contacts and their volume, a drain port is provided within the circular plate.

[0068] While the invention has been detailed and described in the accompanying drawings and foregoing description, such description and description should be considered illustrative or exemplary rather than restrictive. It should be understood that changes and modifications can be made by those skilled in the art within the scope of the following claims. Specifically, the invention covers further embodiments having any combination of features from the different embodiments described above and below. Furthermore, the statements characterizing the invention herein relate to embodiments of the invention and are not necessarily limited to all embodiments.

[0069] The terminology used in the claims should be interpreted as having the broadest reasonable interpretation consistent with the foregoing description. For example, the use of “an” or “the” when introducing an element should not be interpreted as excluding multiple elements. Similarly, the use of “or” should be interpreted as inclusive, so the detail of “A or B” does not exclude “A and B” unless the context or the foregoing description clearly indicates that only one of A and B is intended to be used. Furthermore, the statement “at least one of A, B, and C” should be interpreted as one or more of a set of elements consisting of A, B, and C, and should not be interpreted as requiring at least one of each of the listed elements A, B, and C, regardless of whether A, B, and C are related as a category. In addition, the statement “A, B, and / or C” or “at least one of A, B, or C” should be interpreted as including any single entity from the listed elements (e.g., A), any subset from the listed elements (e.g., A and B), or the entire list of elements (e.g., A, B, and C).

[0070] Figure Labels

[0071] 10 electrical contacts (concave geometry)

[0072] 10a connector

[0073] 11 First end; welding cup opening

[0074] 12 Second End

[0075] 13 Welding Cup Section

[0076] 14 pieces; welding cup base

[0077] 15 inspection ports

[0078] 16 fixed barbs

[0079] 17-block

[0080] 18. Matching geometric structure (concave)

[0081] 19 pieces (metal plates)

[0082] 20 electrical contacts (concave structure)

[0083] 20a connector

[0084] 21 First end; welding cup opening

[0085] 22 Second End

[0086] 23 Welding Cup Part

[0087] 24 pieces (welding cups)

[0088] 25 inspection ports

[0089] 26 Fixed barbs

[0090] 27-block plate

[0091] 28. Matching geometric structure (convex).

[0092] 29 pieces (metal plates)

[0093] System 31

[0094] 31a contact bracket

[0095] 31b Electrical Contact (Concave)

[0096] 32-bit system

[0097] 32a contact bracket

[0098] 32-bit electrical contact (convex)

[0099] LA vertical axis

[0100] Steps S1, S2, and S3

Claims

1. An electrical contact, comprising: a first end; a second end; a fixed barb having a prong or spike projecting outwardly away from a longitudinal axis of the electrical contact; a cup portion formed at the first end, the cup portion configured to be conductively connected by soldering to an electrical component including an electrical wire, wherein the cup portion includes a circumferential wall region having an upper edge defining a cup opening at the first end and a cup base disposed opposite the cup opening and defining a base of the cup portion, and wherein the electrical contact is stamped from a sheet of metal such that a joint is formed extending along a surface of the electrical contact and parallel to the longitudinal axis; wherein the fixed barb is disposed at the joint.

2. The electrical contact of claim 1, wherein, The electrical contact has a convex or concave geometry at the second end opposite the cup portion at the first end.

3. The electrical contact of claim 1, wherein the cup base includes a substantially circular tab stamped from the sheet of metal and bent toward the longitudinal axis of the electrical contact and the cup opening.

4. The electrical contact of claim 1, wherein the cup base has a drain.

5. The electrical contact of claim 1, wherein, An inspection port is disposed in the circumferential wall region of the cup portion.

6. The electrical contact of claim 5, wherein the inspection port is formed between adjacent longitudinal edges of the sheet of metal from which the electrical contact is formed.

7. The electrical contact of claim 1, wherein the electrical contact is composed of a bronze.

8. The electrical contact of claim 1, wherein a baffle is disposed between the base portion of the cup portion and the second end.

9. The electrical contact of claim 4, wherein the drain is disposed substantially in the middle of the cup base.

10. The electrical contact of claim 7, wherein the electrical contact has a nickel, tin, and / or gold plating.

11. A system, comprising: a plurality of electrical contacts according to claim 1, wherein each of the plurality of electrical contacts is embedded or inserted into a contact holder, and wherein the contact holder includes an electrically insulating material.

12. A method of manufacturing an electrical contact according to claim 1, comprising: providing a conductive sheet of metal; stamping and forming the electrical contact from the conductive sheet of metal; and obtaining the cup portion by bending a circular tab toward a longitudinal axis of the electrical contact.

13. The method of claim 12, further comprising applying a plating to the electrical contact. ​

Images