Connection assembly and method for forming connection assembly

Abstract

The invention relates to a press-fitted contact element, comprising at least two press-fitting regions, each of which is ultimately formed on an edge contour of the press-fitted contact element along a spaced-apart press-fitting axis extending in each case parallel to one another. In addition, the at least two press-fitting regions have a plating coating and have a spacing dimension from each other in the direction of the press-fitting axis. In this case, the at least two press-fitting regions are respectively formed on sub-contact elements, which are connected to one another at the connection ports in order to form a press-fitting contact element.

Description

Technical Field

[0001] The invention relates to a press-fit contact element, a method for producing the same and a sheet metal assembly for use in the method according to the preambles of the independent claims. Background Art

[0002] Press-fit technology is a known and reliable connection technology for making electrical and / or mechanical contact between connecting partners. Therefore, electrical devices, for example, have press-fit pins, by means of which, for example, electrical components or electrical assemblies are electrically contacted with the circuit carrier. In order to obtain a press-fit contact with reliable quality, the press-fit pin must have a press-fit area, which can be pressed into a complementary recess in the circuit carrier under defined conditions. The defined conditions relate in particular to the geometric matching dimensions and matching materials of the connecting partner in the area where the press-fit contact is to be formed. In this regard, the press-fit pin has a coating made of a suitable material and including outer dimensions with specified tolerances in the area of ​​the press-fit area. The coating is applied, for example, by means of an electroplating process, in which such a press-fit pin can be kept in the strip and manufactured automatically in large quantities by continuously moving the strip under a coating device.

[0003] Also known are press-fit contact elements with a plurality of press-fit zones, which are used, for example, to electrically contact a plurality of circuit carriers arranged one above the other. To this end, the press-fit zones must be located at different heights. However, due to the staggered heights of the press-fit zones, the required electroplated coating thicknesses for these press-fit zones cannot be guaranteed due to manufacturing conditions. For this reason, press-fit contact elements with a plurality of press-fit zones have hitherto been forced to be stamped at the same height in order to be subsequently adjusted to the correct height by complex bending processes. However, this would worsen the achievable tolerances of the position of the press-fit zones and would also make the press-fit contact element more expensive.

[0004] It is generally known to connect very complex sheet metal parts to one another by welding. The orientation of the sheet metal connecting parts is achieved by a corresponding orientation geometry. Summary of the invention

[0005] The invention is based on the object of providing a press-fit contact element with minimized tolerances and at low cost, which has a plurality of press-fit regions arranged at different heights.

[0006] This object is achieved by a press-fit contact element, a method for its production and a sheet metal assembly for use in the method having the features of the characterizing parts of the independent claims.

[0007] The present invention first proposes a press-fit contact element, which includes at least two press-fit areas, which are respectively formed on the edge contour of the press-fit contact element along press-fit axes extending parallel to each other. In addition, at least two press-fit areas have a plating coating and have a spacing dimension between each other in the direction of the press-fit axis. Here, at least two press-fit areas are respectively formed on sub-contact elements, which are connected to each other at a connection port to form a press-fit contact element. Advantageously, the sub-contact element can form an optimal plating coating in advance at least in the area of ​​its press-fit area, regardless of how it is finally arranged in the press-fit contact element. Then, after the electroplating process, a geometric arrangement of press-fit areas of different sub-contact elements that have been provided with a plating coating is formed with a small azimuthal position tolerance by means of simple connection technology. In large-scale or batch manufacturing, the cost of such a press-fit contact element can be advantageously reduced. These advantages can bring benefits especially when the height spacing dimension of the press-fit area is large. Therefore, it is preferably implemented in the described manner with a spacing dimension greater than 7 mm, in particular greater than 10 mm, for example greater than 15 mm.

[0008] Further developments and improvements of the press-pack contact element according to the invention can be achieved by means of the measures listed in the dependent claims.

[0009] A preferred embodiment of the press-fit contact element provides that the connection port comprises a material connection, a force transmission connection and / or a form-fit connection. The form-fit connection can advantageously be used for the correct orientation positioning of the sub-contact elements relative to each other, while the force transmission connection and / or the material connection hold the sub-contact elements in the correct orientation position, in particular permanently hold them together in the form of a press-fit contact element. Overall, in this way, a very rigid press-fit contact element can also be formed as required, so that press-fitting areas arranged at a certain height spacing can be press-fitted simultaneously or sequentially without deformation during press-fitting. This is particularly suitable for low-cost embodiments of press-fit contact elements, in which the sub-contact elements connected to each other are arranged in the same orientation plane, in particular in the area of ​​the connection port.

[0010] The embodiment of the press-fit contact element in which the sub-contact elements are respectively stamped sheet metal parts or laser cut sheet metal parts and the press-fit contact elements extend in the same substrate plane of the sub-contact elements brings particular advantages. With this embodiment, the sub-contact elements can be manufactured on conventional sheet metal processing equipment, for example on a stamping equipment or a laser cutting equipment, in particular in a highly automated and precise manner. In addition, the press-fit area can also be manufactured with high precision by a mature stamping process. Finally, the sheet metal can be provided in the form of a strip. Therefore, the intermediate product state of the sub-contact element in the sheet metal composite formed by the strip can also be coated with a galvanic coating at least on the press-fit area in a highly automated production in which the layer thickness can be adjusted very precisely.

[0011] In a preferred improvement of the press-fit contact element, the sub-contact elements have outer contours that complement each other in the area of ​​the connection port. Here, these outer contours that complement each other are joined to each other in a jigsaw-like manner in a form-fitting manner, thereby forming at least one form-fitting connection and / or force-transmitting connection. This enables the sub-contact elements to be positioned correctly relative to each other and enables a simple connection of the sub-contact elements to each other. A variety of possible complementary outer contours are conceivable, which can be used for the mentioned purposes depending on the application scenario.

[0012] In another advantageous embodiment of the press-fit contact element, at least one of the sub-contact elements has at least one further press-fit region. In this case, all press-fit regions of the at least one sub-contact element are arranged in the same azimuthal plane, which is oriented perpendicular to the press-fit axis. With the aid of the further press-fit regions, a plurality of different, required contact points can be electrically contacted simultaneously using a single press-fit process, such as contact points of an electronic circuit arranged on a circuit carrier. Multiple contacting can also ensure, for example, current carrying capacity and / or mechanical stability.

[0013] The present invention also relates to a method for producing a press-fit contact element, in particular according to at least one of the above-mentioned embodiments. The method comprises at least the following method steps:

[0014] a) forming at least two sub-contact elements with different contours from a substrate, each of which includes at least one press-fit region,

[0015] b) applying a galvanic coating at least in the region of at least one press-fit region of at least two partial contact elements,

[0016] c) connecting at least two sub-contact elements in the area of ​​the connection port to form a press-fit contact element, so that at least one press-fit area formed respectively on at least two sub-contact elements with different contours are arranged on press-fit axes parallel to each other and have a spacing dimension relative to each other in the direction of the press-fit axis.

[0017] For the press-fit contact element manufactured in this way, although the height of the press-fitting area included is staggered, the layer thickness of the electroplated coating applied thereon can still be advantageously guaranteed with high precision. This ensures that all press-fitting areas have the same press-fitting conditions, so that high process reliability can be maintained. In addition, the required position of the press-fitting area can be maintained with very small tolerances. The sub-contact element is formed in particular from a strip and / or a sheet. The contour of the sub-contact element can be conveniently and accurately completed in particular by a cutting process, such as a stamping process or a laser cutting process. The press-fitting area can also be formed precisely by a known punching process, for example with mature press-fitting geometric shape dimensions.

[0018] The following embodiment of the method brings particularly great advantages, in which in method step a) a plurality of at least two sub-contact elements with different contours are respectively formed in a common, continuous strip and / or sheet as a sheet metal composite. In this case, each of the sub-contact elements is held in the sheet metal composite by at least one connecting strip formed by the strip and / or sheet metal. Each sub-contact element is not separated until after method step b) and before method step c) by cutting off at least one connecting strip that serves to hold it. As a result, known electroplating process equipment can be easily used, which applies a coating to sheet metal strips of the described type for the highest possible production. Therefore, the adjustment of the method is very advantageous by arranging the pressing areas of a plurality of at least two sub-contact elements with different contours included in the sheet metal composite in the strip running direction of the continuous strip and / or sheet metal in a common coating area. In method step b), the electroplating coating is applied in the common coating area by means of a coating device during a relative, in particular continuous, movement of the sheet metal composite and the coating device between each other. In this way, the same coating conditions are achieved for each formed pressing area of ​​each sub-contact element during the production process.

[0019] For a correctly oriented and secure connection, in a preferred embodiment of the method, it is provided that in method step a), at least two sub-contact elements with different contours are formed by contour sections having mutually complementary outer contours. In method step c), at least two sub-contact elements are joined to each other in a jigsaw-like manner in the region of the complementary outer contours to form a connection port as a positive connection and / or a force-transmitting connection.

[0020] In order to ensure the connection of the sub-contact elements more firmly and permanently, an advantageous embodiment of the method is characterized in that at least two sub-contact elements are connected to one another in the region of the connection port only or additionally by means of a material connection. Such a material connection can be realized, for example, in the form of a welded connection, an adhesive connection or a soldered connection. A force-transmitting connection can also be realized by means of caulking or a press fit. In particular, by arranging the sub-contact elements in a common plate plane, a special connection concept can be realized which simultaneously has a high rigidity.

[0021] The present invention also relates to a sheet metal composite, which is particularly used for a method according to any one of the aforementioned embodiments. The sheet metal composite comprises a plurality of at least two sub-contact elements with different profiles located in a common continuous strip and / or sheet. These sub-contact elements are respectively held in the sheet metal composite by at least one connecting strip formed by the strip and / or sheet. In addition, these sub-contact elements each have at least one press-fitting area and are arranged in the sheet metal composite so that their respective at least one press-fitting area is arranged successively parallel to the edge of the strip and / or sheet.

[0022] In a particularly preferred embodiment of the sheet metal composite, a portion of the outer contour lines of at least two sub-contact elements with different contours are complementary to each other, so that the at least two sub-contact elements with different contours form a press-fit contact element according to at least one of the above-mentioned embodiments by being joined to each other in a jigsaw-like manner by the complementary outer contour lines in a form-fitting manner in a separated state. The sub-contact elements are separated by being separated from the sheet metal composite at the corresponding retaining connecting strips.

[0023] Furthermore, great advantages are achieved in an embodiment of the sheet metal composite in which the sheet metal composite has a galvanic coating at least in the region of a pressing zone arranged successively and parallel to the edge of the strip and / or sheet metal.

[0024] Overall, the same advantages are achieved as have already been mentioned for the above-described press-pack contact element and the method for producing a press-pack contact element. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Further advantages, features and details of the invention are apparent from the following description of preferred exemplary embodiments and from the accompanying drawings. The drawings show:

[0026] Figure 1 A sheet metal composite comprising at least two partial contact elements with different contours is shown in a top view during the production process of a press-fit contact element,

[0027] Figure 2 A press-fit contact element consisting of two partial contact elements connected in a connection port is shown in a plan view, wherein each partial contact element has a press-fit region with a galvanic coating. DETAILED DESCRIPTION

[0028] In the figures, components with the same function are respectively provided with the same reference numerals.

[0029] Figure 1A sheet metal composite 200 is shown which comprises at least two sub-contact elements 10, 20 of different contours during the production process of a press-fit contact element 100. In particular, a metal strip and / or sheet 210, for example made of copper or a copper alloy, is used as the base material of the sheet metal composite 200. The strip and / or sheet 210 preferably has a conveying structure 220 in the region of an end edge 211 to enable convenient conveying of the strip and / or sheet 210 through at least one processing device 300, 400. The conveying structure 220 can be, for example, in the form of perforations into which moving conveying elements of the processing device 300, 400 can engage and move the strip and / or sheet 210 continuously or in a clocked manner in a defined conveying direction A. In particular, in a highly automated production process, a large number of at least two sub-contact elements 10, 20 of different contours are produced as part of the sheet metal composite 200. Each sub-contact element 10, 20 has at least one, two, three or more press-fitting regions 11, 21. In particular, such press-fitting areas 11, 21 are introduced by known punching processes while forming a defined geometric shape (not shown). The press-fitting areas 11, 21 of all sub-contact elements 10, 20 to be formed are arranged successively along the strip running direction A. In the embodiment shown, the press-fitting areas 11, 21 are arranged adjacent to each other on the side of the perforation 220 away from the end edge 211. The orientation of each sub-contact element 10, 20 relative to its end edge 211 in the strip and / or sheet 210 is also predetermined. The final arrangement of the sub-contact elements 10, 20 relative to each other in the strip and / or sheet 210 is carried out according to the application scenario, preferably with the goal of reducing the production of scrap. In this embodiment, an alternating sequence of a first sub-contact element 10 and a second sub-contact element 20 having a different profile from the first sub-contact element 10 is shown. The second sub-contact element 20 is designed to be significantly larger in size than the first sub-contact element 10. Between two adjacent second sub-contact elements 20, a surface area of ​​the substrate 210 remains, in which the first sub-contact element 10 can be arranged and still maintain a sufficient distance from the respective adjacent second sub-contact element 20. The corresponding shape contours of the sub-contact elements 10, 20 are formed by means of material separation, for example, by a punching process or a laser cutting process. In large-scale or batch production, the material separation is carried out in different chronological stages. Figure 1 In the material separation stage shown, each sub-contact element 10, 20 is still held in the sheet metal composite 200 by at least one connecting strip 212 formed by a strip and / or sheet 210. Such multiple material separation stages can be performed in the same punching device or laser cutting device 300. Depending on the manufacturing situation, the individual material separation stages can also be performed by different devices 300.

[0030] At least two sub-contact elements 10, 20 with different contours are formed by contour sections with outer contour lines 12, 22 that are formed to complement each other. They form a joint geometry 30 in a precisely matched manner. One of the sub-contact elements 10, 20 with different contours, for example, has an inward recess 23a in a part of its outer contour line 22, into which a protruding matching structure 23b extends. The other of the sub-contact elements 10, 20 with an outer contour line 12 complementary to this has a surface area 13a protruding outward, which corresponds to the geometry of the recess 23a mentioned above. In addition, an inward recess structure 13b is introduced into the surface area 13a, which corresponds to the matching structure 23b mentioned above in terms of geometry. However, other joint geometries 30 coordinated with each other can also be conceived.

[0031] In the area of ​​the press-fitting areas 11, 21 arranged in the sheet metal composite 200, a coating area 35 is provided along the strip running direction A. In this coating area, a coating 36, in particular an electroplated coating, is applied on at least the press-fitting areas 11, 12 by means of a coating device 400. In this way, the same defined press-fitting conditions are ensured for these press-fitting areas. This can be done at a manufacturing time point after only the press-fitting areas 11, 12 are formed in the strip and / or sheet 210 by means of cutting and punching processes. Only after the coating is completed, the corresponding contour lines adjacent to the press-fitting areas 11, 12 of at least two sub-contact elements 10, 20 with different contours and the corresponding connecting strips 212 that play a retaining role are formed by corresponding material separation. However, it is also conceivable to apply the coating 36 in the coating area 35 only after at least two sub-contact elements 10, 20 with different contours are formed in the sheet metal composite 200.

[0032] After the partial contact elements 10, 20 have been formed and the included press-fit regions 11, 12 have been coated 36, all partial contact elements 10, 20 are separated from the sheet metal composite 200. This is done by cutting through the retaining connecting strips 212, for example by a further punching process or a laser cutting process.

[0033] As an alternative to the method described above until at least two sub-contact elements 10, 20 with different contours are separated, it is also conceivable to form at least two sub-contact elements 10, 20 with different contours in different strips and / or plates 210. Therefore, different sheet metal composites 200 are formed according to the number of sub-contact elements 10, 20 with different contours, and only sub-contact elements 10, 20 of the same type are manufactured and separated in each sheet metal composite.

[0034] Subsequently, at least two sub-contact elements 10 , 20 having different contours are connected to one another to form a press-fit contact element 100 . Figure 2This press-fit contact element 100 is shown in a top view. In particular, the outer contours 12 and 22 that complement each other are joined to each other in a jigsaw-like manner, so that the above-mentioned joining geometry 30 is represented as a connection port 31. In this case, the connection port 31 is thus particularly configured as a form-fit connection and / or a force-transmitting connection I. The form-fitting connection I ensures that the two sub-contact elements 10 and 20 are precisely positioned relative to each other. The constructed force-transmitting connection I then realizes a fixed and possibly permanent connection. The force-transmitting connection I can also be realized, for example, by caulking or other corresponding methods. In order to ensure a permanent connection, a material connection II can be formed in the connection port 31 alternatively or additionally. For example, a welding contact, a soldering contact or an adhesive contact is suitable for this. The material connection II can also be realized, for example, by limiting the corresponding connection material to be formed locally and, if necessary, in a point-shaped manner at one or more provided connection locations, for example, by means of a welding point of the substrate comprising the two sub-contact elements 10 and 20. In this embodiment, the sub-contact elements 10, 20 are arranged in a common board plane for connection. In other embodiments not shown, different arrangements may be adopted, but the same principle is followed.

[0035] Figure 2 The press-fit contact element 100 shown in FIG. 1 has a total of four press-fit regions 11, 21, which are all along press-fit axes E that are parallel to each other and spaced apart. Three of the press-fit regions 21 are arranged in the same azimuthal plane L2 oriented perpendicularly to the press-fit axis E and are part of the second sub-contact element 20. The other press-fit region 11 is part of the first sub-contact element 10 and is arranged in an azimuthal plane L1 parallel to the azimuthal plane L2. Therefore, the press-fit region 11 has a spacing dimension x relative to the other three press-fit regions 21 in the direction of the press-fit axis E. Despite the spacing dimension x, all press-fit regions 11, 21 have the same coating properties, in particular with regard to dimensional tolerances of external geometric dimensions and / or coating thickness, regardless of which of the sub-contact elements 10, 20 with different contours these press-fit regions belong to. In an embodiment not shown, the press-fit contact element 100 can be formed by more than two sub-contact elements 10, 20. In addition, the corresponding sub-contact elements 10, 20 in different combinations can have one, two, three or more press-fitting areas 11, 21. In addition, the spacing dimension x can be adaptively adjusted according to application requirements, especially a spacing dimension greater than 7 mm, especially greater than 10 mm, for example, greater than 15 mm. When there are more than two sub-contact elements 10, 20, the press-fitting areas 11, 21 of at least two sub-contact elements 10, 20 can have different spacing dimensions x in the direction of the press-fitting axis E.

Claims

1. A press-fit contact element (100), comprising at least two press-fit regions (11, 12), which are respectively formed on an edge contour of the press-fit contact element (100) along press-fit axes (E) extending parallel to each other and spaced apart from each other, wherein: The at least two press-fitting areas (11, 21) have an electroplated coating (36) and have a spacing dimension (x) between them in the direction of the press-fitting axis (E), It is characterized in that The at least two press-fit regions (11, 21) are respectively formed on sub-contact elements (10, 20), and the sub-contact elements are connected to each other at a connection port (31) to form the press-fit contact element (100).

2. The press-fit contact element (100) according to claim 1, It is characterized in that The spacing dimension (x) is greater than 7 mm, in particular greater than 10 mm, for example greater than 15 mm.

3. The press-fit contact element (100) according to claim 1 or 2, It is characterized in that The connection port (31) comprises a material connection portion, a force transmission connection portion and / or a form-fitting connection portion.

4. The press-fit contact element (100) according to claim 3, It is characterized in that The sub-contact elements (10, 20) have outer contour lines (12, 22) that complement each other in the area of ​​the connection port (31), wherein the outer contour lines (12, 22) that complement each other are joined to each other in a puzzle-like shape-fitting manner to form at least one shape-fitting connection portion and / or force-transmitting connection portion (I).

5. The press-fit contact element (100) according to any one of the preceding claims, It is characterized in that The partial contact elements (10, 20) are arranged in the same azimuthal plane, in particular in the region of the connection port (31).

6. The press-fit contact element (100) according to any one of the preceding claims, It is characterized in that At least one of the sub-contact elements (10, 20) has at least one additional press-fitting area (11, 22), wherein all press-fitting areas (11, 22) of the at least one sub-contact element (10, 20) are arranged on the same azimuthal plane (L1, L2) oriented perpendicularly to the press-fitting axis (E).

7. The press-fit contact element (100) according to any one of the preceding claims, It is characterized in that The sub-contact elements (10, 20) are respectively punched sheet metal parts or laser cut sheet metal parts, and the press-fit contact element (100) extends in the same substrate plane of the sub-contact elements (10, 20).

8. Method for producing a press-fit contact element (100), in particular a press-fit contact element (100) according to any one of claims 1 to 7, comprising the following method steps: a) in particular by means of a cutting process and a punching process, forming at least two sub-contact elements (10) with different contours from a base material, in particular from a strip and / or a plate, each of which comprises at least one press-fit region (11, 21), b) applying a galvanic coating (36) at least in the region of at least one press-fit region (11, 22) of at least two partial contact elements (10, 20), respectively, c) connecting the at least two sub-contact elements (10, 20) in the area of ​​the connection port (31) to form the press-fit contact element (100), so that at least one press-fit area (11, 22) respectively formed on at least two sub-contact elements (10, 20) with different contours are arranged on press-fit axes (E) parallel to each other and have a spacing dimension (x) relative to each other in the direction of the press-fit axis (E).

9. The method for forming a press-fit contact element (100) according to claim 8, It is characterized in that In method step a), a plurality of at least two sub-contact elements (10, 20) having different contours are respectively formed in a common, continuous strip and / or sheet (210) as a sheet metal composite (200), wherein each of the sub-contact elements (10, 20) is held in the sheet metal composite (200) by at least one connecting strip (212) formed by the strip and / or sheet (210), and each of the sub-contact elements is not separated until after method step b) and before method step c) by cutting off the corresponding at least one connecting strip (212).

10. The method for producing a press-fit contact element (100) according to claim 9, It is characterized in that A plurality of pressing areas (11, 21) of at least two sub-contact elements (10, 20) of different contours included in the sheet metal composite (200) are arranged in a common coating area (35) along the strip running direction (A) of a continuous strip and / or sheet (210), and in method step b) the electroplated coating (36) is applied in the common coating area (35) by means of a coating device (400) during a relative, in particular continuous, movement of the sheet metal composite (200) and the coating device (400) between each other.

11. Method for producing a press-fit contact element (100) according to any one of claims 8 to 10, It is characterized in that In method step a), at least two sub-contact elements (10, 20) having different contours are formed respectively by contour segments having outer contour lines (12, 22) that complement each other, and in method step c), the at least two sub-contact elements (10, 20) are joined to each other in a puzzle-like manner in the region of the complementary outer contour lines (12, 22) to form a connection port (31) as a form-fitting connection and / or a force-transmitting connection (I).

12. Method for producing a press-fit contact element (100) according to any one of claims 8 to 11, It is characterized in that The at least two sub-contact elements (10, 20) are connected to one another in the region of the connection port (31) by means of a material connection (II), such as a welded connection or a soldered connection, in particular in order to arrange the sub-contact elements (10, 20) in a common plate plane.

13. A sheet metal composite (200), in particular for use in a method for producing a press-fit contact element (100) according to any one of claims 8 to 12, the sheet metal composite correspondingly comprising a plurality of at least two sub-contact elements (10, 20) with different contours located in a common, continuous strip and / or sheet (210), wherein: The sub-contact elements (10, 20) are respectively held in the sheet metal composite (200) by at least one connecting strip (212) formed by the strip and / or sheet (210) and respectively have at least one pressing area (11, 21), wherein the sub-contact elements (10, 20) are arranged in the sheet metal composite (200) such that at least one pressing area (11, 21) of each sub-contact element is arranged successively parallel to an edge (211) of the strip and / or sheet (210).

14. The panel composite (200) according to claim 13, It is characterized in that Parts of the outer contour lines (12, 22) of the at least two sub-contact elements (10, 20) with different contours complement each other, so that the at least two sub-contact elements (10, 20) are respectively separated from the sheet metal composite (200) at the corresponding retaining connecting strips (212) to form a press-fit contact element (100) according to any one of claims 1 to 8 by being joined to each other in a puzzle-like shape by the complementary outer contour lines (12, 22).

15. The panel composite (200) according to claim 13 or 14, It is characterized in that The sheet metal composite (200) has a galvanic coating (36) at least in the region of press-fitting zones (11, 21) arranged successively and parallel to the edge (211) of the strip and / or sheet metal (210).

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