Electrical contact element and electrical connector

Abstract

The invention relates to an electrical contact element (1) and an electrical connector. The electrical contact element is formed from a reformed sheet metal workpiece (2) and is at least substantially sleeve-shaped, having an abutment edge (5) formed from a first end (3) and a second end (4) of the reformed sheet metal workpiece (2). At least one tab (6) is formed at the first end (3) of the reformed sheet metal workpiece (2) along the abutment edge (5). The tab (6) covers an end portion (7) of the second end (4) in a transverse direction with respect to the central axis (M) of the contact element (1), which end portion is opposite the first end (3) of the reshaped sheet metal workpiece (2) along the abutment edge (5), and wherein at least one main curved edge (8) of the tab (6) extends at least substantially orthogonally to the abutment edge (5), the tab (6) is laterally curved around the main curved edge with a front free end (9) of the tab.

Description

Technical Field

[0001] The present invention relates to an electrical contact element according to the preamble of claim 1, the electrical contact element being formed from a reshaped sheet metal workpiece and being at least substantially sleeve-shaped, the electrical contact element having mating edges formed by a first end and a second end of the reshaped sheet metal workpiece.

[0002] The present invention also relates to an electrical connector comprising at least one electrical contact element. Background Technology

[0003] Various electrical connectors are known in electrical engineering. Known electrical connectors are used to transmit power and / or data signals to corresponding mating connectors. Connectors or mating connectors can in particular be plugs, printed circuit board connectors, panel connectors, sockets, couplings, or adapters. In the context of this invention, the terms "connector" and "matting connector" represent all variations.

[0004] The manufacture of electrical connectors typically requires economical manufacturing processes, especially in order to enable mass production at low unit costs. In this context, contact elements are often manufactured as stamped and bent parts, that is, contact elements are typically stamped from sheet metal workpieces or sheets and bent into the desired shape (e.g., bent into a sleeve shape).

[0005] To attach a contact element to another connector component, such as a surrounding housing component, the contact element typically has a detent protrusion stamped from a sheet metal workpiece and bent accordingly. The stamping and bending of this detent protrusion naturally creates openings in the contact element, which reduces its mechanical stability (especially in the case of sleeve-shaped contact elements, where this disrupts the stable sleeve geometry). Openings in the contact element can also impair its electrical properties (e.g., in the case of external conductor contact elements, potentially compromising their shielding effectiveness).

[0006] In particular, if the stamped brake pad is formed in the region of the mating edge between the two ends of a sheet metal workpiece reshaped into a sleeve shape, the mechanical stability of the contact element may be particularly compromised. In this case, the brake pad itself is typically mechanically weakened because it consists of two halves formed from the respective ends of the sheet metal workpiece. Summary of the Invention

[0007] In view of the prior art, the object of the present invention is to provide an electrical contact element with optimized mechanical and electrical properties, which is preferably also economical to manufacture in mass production.

[0008] Another object of the present invention is to provide an electrical connector with electrical contact elements having optimized mechanical and electrical properties, and preferably also being economically manufactured in mass production.

[0009] This objective is achieved for electrical contact elements having the features listed in claim 1. With respect to electrical connectors, this objective is achieved by the features of claim 15.

[0010] The dependent claims and features described below relate to advantageous embodiments and variations of the invention.

[0011] The present invention relates to an electrical contact element formed from a reshaped sheet metal workpiece or sheet metal element (i.e., from a predominantly flat metal component) and being at least substantially sleeve-shaped. The electrical contact element has mating edges formed by a first end and a second end of the reshaped sheet metal workpiece.

[0012] The fact that the sheet metal workpiece is at least substantially sleeve-shaped can be understood to mean that the contact elements are at least partially and substantially completely closed in the circumferential direction or in the cross-section. However, one or more slots in the axial and / or circumferential directions may be retained in the region of the mating edges. Furthermore, recesses or openings may be provided in the sheet metal workpiece. It should also be mentioned that the ends that curve toward each other in the region of the mating edges do not necessarily have to be connected or in contact with each other. The two ends may also be spaced apart from each other, provided they at least partially have an approximately annular cross-section.

[0013] Within the meaning of this invention, the contact element can be described as at least substantially sleeve-shaped, especially if the function of the sleeve (e.g., as protection, guidance, or for accommodating other connectors or cable components) can be realized, even if there are geometric deviations from an ideal sleeve.

[0014] Preferably, the contact element has at least a sleeve-like geometry, that is, the contact element may have, for example, an elongated, hollow, generally cylindrical or conical shape for accommodating or enclosing additional connectors or cable components.

[0015] Electrical contact elements can have circular, elliptical, rectangular, polygonal, or other cross-sectional profiles.

[0016] In this document, "butting edge" specifically refers to the edge or surface where the two ends of a sheet metal workpiece meet in a reshaped state. Therefore, the butting edge is generated only by reshaping or joining the ends, and is thus formed by both ends together. This means that each end preferably has its own butting surface at its edge, where these edges that meet or align (but do not necessarily have to contact) each other form the butting edge. In the context of this invention, the term "butting edge" may also refer to or include the joint or gap between the ends.

[0017] According to the invention, at least one tab is formed along the mating edge at at least the first end of the reshaped sheet metal workpiece.

[0018] The tab can be designed to perform any mechanical and / or electrical function on the contact element or within an electrical connector equipped with the contact element. Preferably, the tab is a braking tab, which allows the contact element to be latched or locked to another connector or cable component, or latched or locked within another connector or cable component (particularly within a connector component surrounding the contact element, such as a contact element carrier or connector housing, or locked to a dielectric inserted into the contact element).

[0019] Alternatively or additionally, the tab may also be an electrical contact tab for contacting another conductive connector or cable component or a mating contact element of a mating connector.

[0020] According to the invention, the tab is configured to cover the end portion of the second end in a transverse direction relative to the central axis of the contact element, the end portion being opposite the first end of the reshaped sheet metal workpiece along the mating edge (i.e., the cover preferably appears in a top view of the contact element oriented toward the central axis). At least one main curved edge of the tab extends at least substantially orthogonal to the mating edge, and the tab is laterally curved around the main curved edge using its front free end.

[0021] The fact that the path of the main curved edge of the tab extends at least substantially orthogonally to the mating edge can be particularly understood as a deviation from the orthogonal path of less than 45°, preferably less than 20°, and more preferably less than 5°. Particularly preferred is that the main curved edge of the tab extends orthogonally to the mating edge.

[0022] Particularly preferred is that the front free end of the tab bends laterally outward, i.e., away from the central axis. Therefore, the tab can protrude outward from the outer lateral housing of the contact element. Thus, the contact element can be housed and secured in another component (e.g., in a contact element carrier, in a dielectric, or in a connector housing) or electrically contact said component (e.g., an anti-contact element or a separate external conductor component).

[0023] However, in principle, the tab can also be bent toward the central axis. Therefore, the tab can protrude inward from the inner sheath of the contact element. Thus, the contact element can, for example, internally house and secure another component (e.g., a dielectric, especially if the contact element is designed as an outer conductor contact element) and / or can make electrical contact with another component (e.g., a reverse contact element, a separate spring cage for contacting the reverse contact element, or the outer conductor of the cable).

[0024] A contact element can be virtually any contact element (especially an inner conductor or outer conductor contact element). A contact element can also be a single component of a multi-part contact element.

[0025] The tab is generally described below as a single latching tab arranged on the outside of the electrical contact element and the contact element as an external conductor contact element, but this should not be construed as limiting the invention.

[0026] Since the tabs formed at the first end of the sheet metal workpiece at least partially cover the second end of the sheet metal workpiece in its deformed state, the opening beneath the tabs or its negative mechanical and electrical effects can be significantly reduced. In particular, as a result, the electrical characteristics of the contact elements can be improved, such as the shielding effect of the outer conductor contact elements.

[0027] The tabs can be designed to be at least partially resilient, for example, to reversibly move during the assembly of the contact elements into the connector and / or to provide sufficient contact pressure for robust electrical contact or mechanical centering and / or fixation.

[0028] Therefore, in an advantageous improvement of the invention, it can be specifically provided that the tab has an elastic spring portion between its free end and the main curved edge.

[0029] The elastic spring portion is preferably elastic in the transverse direction relative to the central axis of the electrical connector or electrical contact element, such that the free end of the tab can move toward or away from the central axis against the elastic restoring force.

[0030] The elastic spring portion of the tab (which preferably forms the foremost portion of the tab) is preferably a tab-functional portion relevant to the mechanical and / or electrical use of the tab in the electrical connector. Therefore, the elastic spring portion can preferably be used for direct locking and / or contact with individual components. Due to the elasticity of the tab, the tab can engage during assembly of the contact elements using the free end of the tab's front end, for example, engaging behind the undercut of a connector component or engaging in a braking recess of the connector component.

[0031] In one embodiment of the invention, the tab may have an attachment portion extending between the main curved edge and the base point of the tab, the base point being connected to the transverse surface of the sheet metal workpiece.

[0032] The attachment portion is preferably a transition region of the tab that connects the elastic spring portion to the base point of the tab. The base point can form a transition between the tab and another transverse surface or body / plate workpiece in the region of the first end. Therefore, the base point is the region where the tab begins to appear.

[0033] Preferably, the main extending direction of the attachment portion extends at an angle to the main extending direction of the elastic spring portion, preferably at least substantially orthogonal, and particularly preferably orthogonal. This specifically means that the central axis of the tab can extend at an angle between the base point and the free end of the tab. The central axis of the tab can preferably consist of two central axis segments extending at an angle to each other, wherein the central axis segment of the attachment portion can preferably be oriented at least substantially orthogonal to the central axis segment of the spring portion.

[0034] According to an improved embodiment of the present invention, the base point of the tab can be spaced apart from the mating edge along the circumferential direction.

[0035] Preferably, the attachment portion extends at least partially circumferentially from the base point through the sheet metal workpiece or within the transverse housing of the sleeve-shaped contact element. Therefore, it is particularly possible to machine or stamp the attachment portion at least partially from the transverse surface of the sheet metal workpiece while it is not bent.

[0036] Within the scope of this invention, the geometry of the tab can be substantially arbitrary. In particular, with regard to the intended use, the length and width of the tab can be designed to achieve a good technical trade-off between sufficient rigidity and sufficient flexibility, sufficient rigidity for secure fixing (e.g., secure fixing in a braking recess of an adjacent connector component) or for secure electrical contact (e.g., secure electrical contact of another connector component or mating contact element), and sufficient flexibility to prevent scratching or other damage during assembly and also reduce the required assembly force.

[0037] It is possible that the tabs extend along the entire length of the mating edge. However, according to a preferred improvement of the invention, it is possible that the tabs are formed only along a portion of the mating edge.

[0038] In this respect, it should be mentioned that, in principle, multiple tabs can also be formed along the mating edge, and if necessary, starting from both ends of the metal sheet workpiece, i.e., alternately starting from the first and second ends of the metal sheet workpiece. For clarity, the invention will be described below using only a single tab, which should not be construed as limiting.

[0039] In an improved embodiment of the invention, at least one auxiliary bending edge may be formed in the attachment portion, and the attachment portion may bend laterally around the auxiliary bending edge, preferably bending away from the central axis of the contact element, but also bending towards the central axis if required by the application.

[0040] Particularly preferred is that the tab in the attachment portion has a pair of curved edges, which consist of two spaced-apart auxiliary curved edges, around which the attachment portion is laterally curved in opposite directions, such that (in cross-section) the tab preferably has at least a substantially S-shaped curved profile in the attachment portion. Specifically, it can be configured such that, by using the two auxiliary curved edges, the tab first bends from the tangential extension direction to the lateral extension direction, and then again bends from the lateral extension direction to the tangential extension direction.

[0041] In particular, an S-shaped bend can be used to offset the tab relative to the transverse surface of the sheet metal workpiece or contact element in a defined manner. The S-shaped bend path allows the tab, or at least the attachment portion of the tab, to rest tangentially on the transverse surface of the electrical contact element, for example, on the inner or outer side (particularly on the covered portion of the second end).

[0042] In an improved embodiment of the invention, the auxiliary curved edges of the pair of curved edges may be configured to extend at least substantially parallel to each other.

[0043] The auxiliary curved edge of the pair of curved edges can also preferably extend at least substantially parallel to the mating edge.

[0044] The auxiliary curved edge of the pair of curved edges can also preferably extend at least substantially orthogonal to the main curved edge.

[0045] However, in principle, the main bending edge and the auxiliary bending edge can be arranged at any angle relative to each other (suboptimal). For example, it can also be arranged such that the main bending edge and at least one auxiliary bending edge extend at least substantially parallel to each other.

[0046] In an advantageous improvement of the invention, the tabs may be configured to extend at least substantially in an L-shape in a top view.

[0047] Preferably, the first end of the L-shaped tab can thus represent the front free end of the tab (i.e., in particular the elastic spring portion), and the second end of the L-shaped tab can form a base point through which the tab is connected to the metal plate workpiece.

[0048] However, in principle, any route of the tabs from the base point to the free end can be provided, such as Z-shaped, S-shaped, zigzag, or other routes.

[0049] In an improved embodiment of the present invention, the second end of the reshaped metal sheet workpiece may be arranged to extend in a straight line along the mating edge, such that the tabs cover the transverse shell portion extending from the second end.

[0050] The straight path at the second end of the reshaped sheet metal workpiece is specifically understood to mean that the path at the second end has no significant protrusions and / or recesses in the circumferential direction. Therefore, the end face of the second end is preferably completely flat.

[0051] However, in an advantageous improvement of the invention, the second end of the reshaped sheet metal workpiece may also have a laterally projecting lug portion that extends at least partially below the tab.

[0052] Therefore, the second end and the first end can, for example, at least partially engage with each other to form a structure similar to interlocking / meshing or even a puzzle-like structure. If desired, the two ends can also be configured to interlock to provide a form fit (e.g., dovetail joint) in the circumferential direction, thereby preventing the reshaped sleeve-shaped contact element from springing back.

[0053] In an advantageous improvement of the invention, the tab having the attachment portion may be positioned at least partially directly resting on the covered end portion of the second end of the reshaped sheet metal workpiece.

[0054] Therefore, the attachment portion can be particularly advantageous for supporting the elastic spring portion and better supporting the mechanical stability of the contact element as a whole.

[0055] In an advantageous improvement of the invention, it is particularly possible to fasten the attachment portion to the end portion of the second end of the reshaped metal sheet workpiece.

[0056] The fastening can be achieved in any manner in principle. However, it is preferred to provide integral fastening (e.g., welded, brazed, or adhesive connection) and / or form-fit fastening (e.g., latched, locked, or clinch connection).

[0057] It should be mentioned in this regard that the attachment portion may alternatively be spaced apart from the lateral surface of the contact element or sheet metal workpiece, for example, to increase the elasticity of the tab.

[0058] In an improved embodiment of the present invention, the first and second ends of the reshaped metal sheet workpiece may be at least partially connected or fastened to each other along the mating edge.

[0059] Fastening the first end to the second end is not absolutely necessary, but it can be advantageous to avoid unwanted bounce of the sleeve-shaped contact element at the mating edge and to increase mechanical stability.

[0060] As for fastening or connecting the two ends to each other, this can generally be accomplished using any fastening technique, among which integral fastening techniques (e.g., welding, brazing or adhesive bonding) and / or form-fitting fastening techniques (e.g., latching, locking or riveting) may be preferred.

[0061] According to an improved embodiment of the present invention, the free end of the front end of the tab can be aligned in the direction of the cable-side end of the contact element.

[0062] The fact that the front free end of the tab is aligned in the direction of the cable-side end of the contact element has the following advantages: on the one hand, the contact element can be installed from the cable-side end of the connector (which is generally preferred); on the other hand, it provides particularly strong cable pull-up support. However, in principle, the front free end of the tab can be aligned in any direction.

[0063] In an advantageous improvement of the invention, the free end of the front end of the tab may have a chamfer.

[0064] This simplifies the process of joining or assembling electrical contact elements with surrounding components or inserting another component into the contact element.

[0065] In particular, to further support the assembly of the contact elements within the connector, mechanical codes (e.g., one or more protrusions) may optionally be formed at at least one end of the contact element, corresponding to appropriate reverse codes (e.g., recesses or openings) on the mating parts of the connector. This ensures that the contact elements are mounted in the electrical connector only in the correct orientation or phase position.

[0066] The present invention also relates to an electrical connector comprising at least one electrical contact element as described above and below.

[0067] It can be configured that the electrical connector has a contact element carrier and / or a connector housing for receiving at least one contact element.

[0068] The contact element is preferably mounted inside the connector housing and / or the contact element carrier. A tab can lock or latch the contact element inside the connector (e.g., lock or latch it inside the connector housing or the contact element carrier).

[0069] The electrical connector can be configured to have a dielectric material housed within the contact element. A tab can latch or lock the dielectric material within the contact element.

[0070] As mentioned above, the tabs of the contact element can also be used for electrical contact within the connector (e.g., for electrical contact in a conductive housing) or for contact via mating contact elements of the corresponding mating connector.

[0071] The contact element can be an outer conductor contact element, an inner conductor contact element, or any other contact element (or part of a multi-part contact element) of the connector. Preferably, the contact element is designed as an outer conductor contact element.

[0072] Electrical connectors are not limited to specific connector standards or applications. Electrical contact elements can be advantageously applied to both straight and right-angle connectors. This invention is particularly advantageous for cable connectors, printed circuit board connectors, housing connectors, or adapter plugs. Due to the optimized electrical characteristics of the contact elements, this invention is particularly suitable for connectors used in high-frequency technologies (e.g., coaxial connectors), although this should not be construed as limiting.

[0073] The present invention also relates to a method for manufacturing an electrical contact element, the method comprising at least the following steps (these steps do not necessarily have to be performed in a specified order): -Provide sheet metal workpieces; - Reshape the sheet metal workpiece into a geometry that is at least substantially sleeve-shaped, such that a common mating edge is formed by the first and second ends of the sheet metal workpiece; - At least one tab is formed at the first end of the sheet metal workpiece along the mating edge, such that the tab covers the end portion of the second end in the transverse direction relative to the central axis of the contact element, the end portion being opposite the first end of the reshaped sheet metal workpiece along the mating edge; - The front free end of the tab bends in the lateral direction around at least one main bending edge, the main bending edge extending at least substantially orthogonal to the mating edge.

[0074] The features described in connection with one of the objectives of the invention, namely the features given by the electrical contact element according to the invention, the electrical connector according to the invention, and the method for manufacturing the electrical contact element according to the invention, can also advantageously achieve other objectives of the invention. Similarly, the advantages mentioned in connection with one of the objectives of the invention can also be understood to relate to other objectives of the invention.

[0075] It should also be noted that terms such as “comprising,” “having,” or “with” do not exclude other features or steps. Furthermore, terms such as “a” or “described” referring to a single number of steps or features do not exclude multiple features or steps, and vice versa.

[0076] However, in purely explicit embodiments of the invention, it may also be provided that features introduced herein are listed exhaustively using the terms "comprising," "having," or "with." Thus, for example, for each claim, the list of one or more features within the scope of the invention may be considered exhaustive. For instance, the invention may consist solely of the features mentioned in claim 1.

[0077] It should be noted that terms such as “first” or “second” are used primarily for the purpose of distinguishing between the features of the various devices or methods, and are not necessarily intended to imply that the features are interdependent or related to each other.

[0078] Furthermore, it should be emphasized that the values ​​and parameters described herein include deviations or fluctuations of ±10% or less, preferably ±5% or less, more preferably ±1% or less, and very particularly preferably ±0.1% or less, of the corresponding specified values ​​or parameters, provided that such deviations are not excluded in the actual embodiments of the invention. Specifying ranges by starting and ending values ​​also includes all values ​​and fractions contained within the corresponding specified ranges, particularly the starting and ending values ​​and their corresponding average values. Attached Figure Description

[0079] Exemplary embodiments of the present invention will now be described in more detail with reference to the accompanying drawings.

[0080] The accompanying drawings illustrate a preferred exemplary embodiment in which various features of the invention are shown in combination with each other. Features of the exemplary embodiment may also be implemented separately from other features of the same exemplary embodiment, and therefore can be readily combined by those skilled in the art to form further useful combinations and sub-combinations with features of other exemplary embodiments.

[0081] In the accompanying drawings, elements with the same function are given the same reference numerals.

[0082] This is illustrated schematically: Figure 1 According to a first exemplary embodiment of the present invention, a metal plate workpiece for forming a sleeve-shaped contact element, the metal plate workpiece being in a state before re-forming; Figure 2 : Figure 1 A top view of a sleeve-shaped contact element in the reformed state of a sheet metal workpiece; Figure 3 : Figure 1 A perspective view of a sleeve-shaped contact element in the reshaped state of a sheet metal workpiece; Figure 4 : A perspective view of a sleeve-shaped contact element according to a second exemplary embodiment in the reformed state of a sheet metal workpiece; Figure 5 An electrical connector according to an exemplary embodiment, located in a longitudinal section, and according to... Figure 4 Electrical contact elements; Figure 6 According to a third exemplary embodiment of the present invention, a metal plate workpiece for forming a sleeve-shaped contact element is in a state before re-forming; Figure 7 : Figure 6 A top view of a sleeve-shaped contact element in the reformed state of a sheet metal workpiece; Figure 8 According to a fourth exemplary embodiment of the present invention, a metal plate workpiece for forming a sleeve-shaped contact element is in a state before re-forming; Figure 9 : Figure 8 A top view of a sleeve-shaped contact element in the reformed state of a sheet metal workpiece; Figure 10 According to a fifth exemplary embodiment of the present invention, a metal plate workpiece for forming a sleeve-shaped contact element, the metal plate workpiece being in a state before re-forming; Figure 11 According to a sixth exemplary embodiment of the present invention, a metal plate workpiece for forming a sleeve-shaped contact element, the metal plate workpiece being in a state before re-forming; Figure 12 According to a seventh exemplary embodiment of the present invention, a metal plate workpiece for forming a sleeve-shaped contact element is in a state where it has not yet been reshaped. Detailed Implementation

[0083] Figures 1 to 3 An example of a first exemplary embodiment of an electrical contact element 1 according to the present invention is shown. The electrical contact element 1 is formed from a reshaped metal sheet workpiece 2 and is at least substantially sleeve-shaped. Figure 1 The image shows a sheet metal workpiece in its unreshaped state. Figure 2 and Figure 3 The image shows a sheet metal workpiece in a reshaped state. Figure 2 A top view is shown in the direction of the central axis M of contact element 1, and Figure 3 A perspective view is shown.

[0084] In the context of this invention, the metal sheet workpiece 2 is formed in such a way that the first end 3 and the second end 4 of the metal sheet workpiece 2 (see in each case) Figure 1 ) Form a common docking edge 5 (see Figure 2 and Figure 3 A tab 6 is formed at the first end 3 of the reshaped metal sheet workpiece 2 along the mating edge 5 (in principle, multiple tabs 6 may also be provided, and if necessary, tabs extending from the second end 4 of the metal sheet workpiece 2 may also be provided). For clarity, the accompanying drawings show only a single tab 6 extending along a portion of the mating edge 5, but this should not be construed as limiting the invention.

[0085] It can be configured such that the tab 6 is positioned in the transverse direction relative to the central axis M of the contact element 1 (i.e., in the top view, as shown). Figure 2 (as shown) the end portion 7 covering the second end 4 (see) Figure 2 (The dashed and shaded lines in the diagram), the end portion is opposite the first end 3 of the reshaped metal sheet workpiece 2 along the mating edge 5.

[0086] Because the tab 6 covers at least a portion of the second end 4 of the metal sheet workpiece 2, the opening below the tab 6 can advantageously be closed or filled by the end portion 7 of the second end 4 to achieve electrical and mechanical optimization of the contact element 1. Therefore, the contact element 1 can provide improved electrical and mechanical properties compared to the prior art.

[0087] The tab 6 has at least one main curved edge 8, and the tab 6 is laterally curved around the main curved edge 8 by means of its front free end 9. In an exemplary embodiment, the main curved edge 8 extends orthogonally to the mating edge 5.

[0088] In an exemplary embodiment, the tab 6 bends outwards at its free end 9 at its front end, i.e., away from the central axis M of the contact element 1. However, depending on the application, the tab 6 may also be bent inwards, thus protruding into the sleeve-shaped contact element 1.

[0089] The second exemplary embodiment of contact element 1 is similar to the first exemplary embodiment and in Figure 4 As shown in the diagram, the contact element 1 at least substantially corresponds to the first exemplary embodiment in the region of the tab 6, but beyond that, the contact element is more complex in terms of geometry and function. It should be noted at this point that... Figures 1 to 3 and Figures 6 to 12 The contact element 1 shown is merely an example and is intended to illustrate the basic principles of the invention. Figure 4 The contact element 1 has an insertion region 10 and a cable-side base region 11. The insertion region 10 is designed as a spring basket for mating contact elements that mate with a connector (not shown). The cable-side base region 11 is used to secure the contact element to the contact element carrier or connector housing 12. Figure 4 The specific mounting configuration of the contact element 1 in the connector housing 12 of the electrical connector 13 according to an exemplary embodiment of the present invention is as follows: Figure 5 The example is shown in the form of a longitudinal section.

[0090] In an exemplary embodiment, the electrical contact element 1 is, for example, an external conductor contact element and is fixed by the tab 6. Figure 5The connector housing 12 is used as a braking tab in this example, which is locked behind the undercut 14 in the connector housing 12. Assembly can advantageously begin from the cable-side end 15 of the connector 13. In this case, the front free end 9 of the tab 6 is aligned in the direction of the contact element 1 or the cable-side end 15 of the connector 13, and can spring in during assembly and... Figure 5 The contact element 1 will pop back into the final assembly position shown. To facilitate insertion of the contact element 1 into the connector housing 12, the tab 6 may optionally have a chamfer at its front free end 9. Alternatively, mechanical coding may be provided for the contact element 1 to ensure that the contact element 1 is inserted into the connector housing 12 only in a predetermined orientation and alignment.

[0091] As an example, Figure 5 The dielectric 16 within the contact element 1 according to the invention is shown, and further, the inner conductor contact element 17 within the dielectric 16 is shown. The inner conductor contact element 17 and the contact element 1, designed as an outer conductor contact element according to the invention, are connected at the cable-side end 15 of the connector 13 to the corresponding inner conductor 18 and outer conductor 19 of the cable 20. Of course, the specific installation is merely an example and should not be construed as limiting the invention, as the invention is applicable in principle to any type of connector (e.g., also to beveled connectors and non-coaxial connectors). In particular, the contact element 1 according to the invention can also be an inner conductor contact element or other contact elements, such as a support sleeve or other conductive components required within the connector 13.

[0092] The tab 6 has a spring-loaded portion 21 between its free end 9 at its front end and the main curved edge 8. This can preferably be used for latching and / or electrical contact with individual components, such as the aforementioned connector housing 12 of the electrical connector 13. Furthermore, the tab 6 has an attachment portion 22 extending between the main curved edge 8 and a base point 23 of the tab 6, which is connected to the sheet metal workpiece 2. Figures 1 to 11 In the exemplary embodiment shown, the base point 23 is spaced apart from the mating edge 5 in the circumferential direction U (see [reference]). Figure 3 This is such that the attachment portion 22, starting from the first end 3, is at least partially located within the transverse housing of the sleeve-shaped contact element 1 in the circumferential direction U. For this purpose, the attachment portion 22 is preferably machined or stamped out at least partially from the transverse surface 24 of the unbent sheet metal workpiece 2 during manufacturing.

[0093] The location of base point 23 or the distance d from the base point to the mating edge 5 (see details) Figure 1 This can be used to specify the opening formed at the first end 3. As shown by example, Figure 6 and Figure 7The exemplary embodiment of another electrical contact element 1 according to the invention shown is intended to illustrate an alternative position of the base point 23 relative to the mating edge 5 (see [link]). Figure 6 The distance d between the base point 23 and the mating edge 5 changes. It should be noted that a certain opening or a certain width of such opening may typically be required to provide sufficient space for the S-shaped bend of the tab 6 described below. It should also be mentioned that if the distance d between the base point 23 and the mating edge 5 decreases, then during assembly, the tab 6 is positioned increasingly offset from the center of the mating edge 5 in the circumferential direction U (see also...). Figure 2 and Figure 7 Depending on the application, this offset may not be a problem and can be considered by those skilled in the art when designing contact element 1.

[0094] A pair of curved edges 25, consisting of two spaced-apart auxiliary curved edges 26, can be formed in the attachment portion 22 of the tab 6 (see in particular). Figure 1 The attachment portion 22 bends laterally in the opposite direction around the curved edge, as in Figure 3 This can be seen particularly well in the middle. In this way, a preferably at least substantially S-shaped curved path can be produced, whereby the tab 6 and its attachment portion 22 can rest tangentially on the transverse surface 24 of the contact element 1. Figures 1 to 11 In the exemplary embodiment shown, the auxiliary curved edges 26 of the pair of curved edges 25 extend parallel to the mating edge 5 and also orthogonal to the main curved edge 8. Therefore, when viewed from above, the tab 6 can have at least a substantially L-shaped profile.

[0095] However, it should be noted that the L-shaped configuration of the tabs 6, and especially the aforementioned alignment of the curved edges 8 and 26 relative to each other, is not absolutely necessary. For example, see reference... Figure 12 The exemplary embodiment shown exemplifies how the parallel alignment of all curved edges 8, 26 results in the tab 6 having a z-shaped or zigzag configuration in the top view. In principle, many other possibilities exist for implementing the tab 6 according to the invention.

[0096] It can be configured such that the second end 4 of the reshaped sheet metal workpiece 2 extends straight along the mating edge 5, such that the tab 6 covers the transverse shell or end portion 7 extending from the second end 4, as shown below. Figure 2 As already described. In particular, it can be configured such that the second end 4 has no protrusions or recesses in the circumferential direction, as particularly in Figure 6 and Figure 7 This can be clearly seen in the exemplary embodiments shown.

[0097] However, in principle, the second end 4 of the reshaped sheet metal workpiece 2 can also have a laterally protruding lug portion 27, which extends at least partially below the tab 6 in the reshaped state of the sheet metal workpiece 2. In this way, the opening below the tab 6 can be better closed if needed. Therefore, the tab 6 can cover the laterally protruding lug portion 27 of the second end 4, for example, as... Figure 8 and Figure 9 As shown in the exemplary embodiment.

[0098] Especially from Figure 3 It can be seen that the tab 6 with the attachment portion 22 can rest at least partially directly on the covered end portion 7 of the second end 4 of the reshaped sheet metal workpiece 2. The attachment portion 22 can also optionally be fastened to the covered end portion 7 of the second end 4 of the reshaped sheet metal workpiece 2, particularly by integral engagement and / or form-fitting. In this way, the mechanical stability of the contact element 1 can be further improved. An example of the solder joint 28 of the tab 6 is shown in... Figure 3 The middle part is indicated by a dashed line. Alternatively, the first end 3 and the second end 4 of the reshaped sheet metal workpiece 2 may be at least partially connected to each other along the mating edge 5 in an integral and / or shape-fit manner.

[0099] As an example, Figure 10 and Figure 11 Two variations of the advantageous tab 6 are shown, in which... Figure 10 In this context, the distance between the base point 23 and the first end 3 or the mating edge 5 is determined such that when the sheet metal workpiece 2 is in a non-reforming state, the entire tab 6 is located within the sheet metal workpiece 2. Conversely, according to... Figure 11 In the exemplary embodiment shown, the elastic spring portion 21 of the tab 6 fully protrudes from the first end 3 of the metal plate workpiece 2. Figure 10 In the case where the contact element 1 is formed or completed, the opening formed below the protrusion 6 can be closed by means of a corresponding suitable laterally protruding lug portion 27 of the second end 4, while Figure 11 In the exemplary embodiment shown, the second end 4 can extend in a perfectly straight line. However, in Figure 11 In the exemplary embodiment shown, a lug portion 27 (shown as a dashed line) may also be provided as an option to close the opening of the tab 6 in the area of ​​the attachment portion 22.

[0100] Figure 10The undercut is also illustrated by way of example, which can optionally be positioned between the first end 3 and the second end 4 of the sheet metal workpiece 2, such that inserting the second end 4 into the opening beneath the tab 6 simultaneously provides improved mechanical fixation between the first end 3 and the second end 4, thereby preventing the sleeve-shaped contact element 1 from springing up in the area of ​​the mating edge 5. For example, for this purpose, Figure 10 The lug portion in the middle can be conical (shown as dashed lines), so that a dovetail connection can be provided with a corresponding route (also shown as dashed lines) to the other end or the first end 3.

[0101] As already mentioned, the present invention provides many different possibilities for the geometry of the contact element 1, its tab 6, and the coverage of the second end 4 of the sheet metal workpiece 2, so as to at least partially close the opening beneath the tab 6. Therefore, the above examples are not exhaustive or limiting, but should only be understood as examples of the invention.

Claims

1. An electrical contact element (1), said electrical contact element being formed from a reshaped sheet metal workpiece (2) and being at least substantially sleeve-shaped, said electrical contact element comprising a mating edge (5) formed by a first end (3) and a second end (4) of said reshaped sheet metal workpiece (2), wherein, At least one tab (6) is formed at the first end (3) of the reshaped metal sheet workpiece (2) along the mating edge (5). Its features are, The tab (6) covers the end portion (7) of the second end (4) in a transverse direction relative to the central axis (M) of the contact element (1), the end portion being opposite the first end (3) of the reshaped sheet metal workpiece (2) along the mating edge (5), wherein at least one main bending edge (8) of the tab (6) extends at least substantially orthogonally to the mating edge (5), the tab (6) being laterally bent around the main bending edge by means of the front free end portion (9) of the tab.

2. The electrical contact element (1) according to claim 1. Its features are, The tab (6) has an elastic spring portion (21) between the free end (9) of the tab and the main curved edge (8), the elastic spring portion being preferably used for latching and / or contacting with a separate component, and the tab has an attachment portion (22) extending between the main curved edge (8) and the base point (23) of the tab (6), the base point being connected to the transverse surface (24) of the sheet metal workpiece (2).

3. The electrical contact element (1) according to claim 2. Its features are, The base point (23) is spaced apart from the mating edge (5) in the circumferential direction (U).

4. The electrical contact element (1) according to any one of claims 1 to 3. Its features are, The tab (6) is formed only along a portion of the mating edge (5).

5. The electrical contact element (1) according to any one of claims 2 to 4. Its features are, A pair of curved edges (25) are formed in the attachment portion (22), the pair of curved edges consisting of two auxiliary curved edges (26) spaced apart from each other, the attachment portion (22) being laterally curved in opposite directions around the two auxiliary curved edges in each case, such that a curved path at least substantially S-shaped is preferably produced.

6. The electrical contact element (1) according to claim 5. Its features are, The auxiliary curved edge (26) of the pair of curved edges (25) extends at least substantially parallel to the mating edge (5).

7. The electrical contact element (1) according to any one of claims 1 to 6. Its features are, The tab (6) is at least substantially L-shaped in the top view.

8. The electrical contact element (1) according to any one of claims 1 to 7. Its features are, The second end (4) of the reshaped sheet metal workpiece (2) extends in a straight line along the mating edge (5).

9. The electrical contact element (1) according to any one of claims 1 to 7. Its features are, The second end (4) of the reshaped sheet metal workpiece (2) has a laterally protruding lug portion (27) extending at least partially below the tab (6).

10. The electrical contact element (1) according to any one of claims 2 to 9. Its features are, The tab (6) having the attachment portion (22) rests at least partially directly on the covered end portion (7) of the second end (4) of the reshaped sheet metal workpiece (2).

11. The electrical contact element (1) according to claim 10. Its features are, The attachment portion (22) is preferably fastened to the end portion (7) of the second end (4) of the reshaped sheet metal workpiece (2) in an integral and / or form-fit manner.

12. The electrical contact element (1) according to any one of claims 1 to 11. Its features , The first end (3) and the second end (4) of the reshaped sheet metal workpiece (2) are connected to each other at least partially along the mating edge (5) in an integral and / or shape-fit manner.

13. The electrical contact element (1) according to any one of claims 1 to 12. Its features are, The front free end (9) of the tab (6) is aligned in the direction of the cable side end of the contact element (1).

14. The electrical contact element (1) according to any one of claims 1 to 13. Its features are, The front free end (9) of the protrusion (6) has a chamfer.

15. An electrical connector (13) comprising at least one electrical contact element (1) according to any one of claims 1 to 14 and a connector housing (12) and / or a contact element carrier for accommodating at least one contact element (1).

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