FORK CONTACT FOR ELECTRICALLY CONTACTING A CONTACT ELEMENT

Abstract

Fork contact (1) for electrically contacting a contact element, comprising at least one pair of contact legs (3) extending from a base (2) of the fork contact (1) in the vertical direction (z) of the fork contact (1), between which a contact gap (4) exists and which, when the contact element is inserted into the contact gap (4), are elastically expanded in the transverse direction (y) of the fork contact (1) and thereby clamp the inserted contact element between respective contact surfaces (5) of respective clamping areas (6) of the contact legs (3) in the transverse direction (y) of the fork contact (1), wherein the contact legs (3) taper from the base (2) of the fork contact (1) to their clamping areas (6) with respect to a plane spanned by the vertical direction (z) and transverse direction (y), wherein, in the mechanically unloaded state, the contact surfaces (5) of the clamping areas (6) are inclined to the vertical direction (z) of the fork contact (1),that the contact surfaces (5) after the insertion of the contact element run at least substantially parallel to the vertical direction (z) of the fork contact (1), characterized in that the clamping areas (6) have a bulbous contour and a cross-section that is at least substantially constant with respect to the plane spanned by the vertical direction (z) and transverse direction (y).

Description

Technical area

[0001] The present invention relates to a fork contact for electrically contacting a contact element. State of the art

[0002] Electrical components, such as relays, fuses, and the like, or even external add-on modules, often need to be electrically and mechanically connected to one another. Often, such components must also be interchangeably connected via plug-in contacts, for example, to a power distribution board. Such plug-in contacts are typically implemented using box contacts, fork contacts, or multi-lam contacts. Fork contacts, in particular, are advantageous if they can be designed to be particularly compact and optimized in terms of their mechanical and electrical properties.

[0003] DE 10 2012 016 013 A1 discloses an electrical contact element and a construction method for an electrical contact element.

[0004] JP 2013-255 346 A discloses a structure for attaching a busbar.

[0005] US 2010 / 0 178 814 A1 discloses an electrical terminal.

[0006] AT 259 661 B discloses a method for producing fork-shaped edgewise contact springs.

[0007] US 6 554 659 B2 discloses a contact element.

[0008] US 5 759 052 A discloses a common connector. Description of the invention

[0009] It is therefore the object of the present invention to provide a fork contact by means of which a particularly compact design of a fork contact and, in addition, a particularly reliable mechanical and electrical contacting of a contact element by means of the fork contact can be made possible.

[0010] This object is achieved by a fork contact for electrically contacting a contact element having the features of the independent patent claim. Advantageous embodiments with expedient and non-trivial refinements of the invention are specified in the dependent claims.

[0011] The fork contact according to the invention for electrically contacting a contact element comprises at least one pair of contact legs extending from a base of the fork contact in the vertical direction of the fork contact, between which a contact gap exists and which are elastically expanded in the transverse direction of the fork contact when the contact element is inserted into the contact gap and thereby clamp the inserted contact element between respective contact surfaces of respective clamping regions of the contact legs in the transverse direction of the fork contact, wherein the contact legs taper from the base of the fork contact to their clamping regions relative to a plane spanned by the vertical direction and transverse direction.

[0012] For example, a plug-in tongue can be inserted into the contact gap of the fork contact, bringing the plug-in tongue into contact with the respective contact surfaces of the clamping areas of the contact legs and holding it between the contact legs. The fork contact has a geometry that allows for springing in the elastic range. In other words, the geometry of the contact legs is tapered to optimize its expansion so that the largest possible elastic range is achieved. The respective clamping areas of the contact legs are designed so that the contact element to be inserted and contacted does not sink too deeply into the contact gap, i.e., towards the base of the fork contact.

[0013] Due to the inventive design of the fork contact, in particular due to the fact that the contact legs taper from the base of the fork contact to their clamping areas relative to a plane spanned by the vertical and transverse directions, the fork contact can be designed to be particularly short and compact relative to its vertical direction. Because the fork contact can be designed to be particularly short in its vertical direction, the cross-sectional areas of the fork contact can also be reduced accordingly without negatively affecting the current-carrying capacity. The fork contact according to the invention has a particularly large elastic spring area relative to the expansion or widening of the contact legs, while simultaneously achieving particularly good current-carrying capacity.

[0014] The fork contact according to the invention can therefore be designed to be particularly compact, resulting in significant material savings. As a result, the fork contact can be manufactured particularly cost-effectively. Due to the particularly compact design of the fork contact, it requires relatively little installation space, for example, in a power distributor or the like, so that such components can also be designed smaller or more compactly. Overall, the fork contact also requires less installation space, for example, in a motor vehicle in which the fork contact is used.

[0015] Because the fork contact can be designed to be particularly compact, smaller tolerances in the contact gap can also be achieved. With a smaller tolerance field, smaller fluctuations in deformation occur. These lead to lower strains in the material. The strains must remain elastic. Furthermore, the compact design of the fork contact also contributes to the fork contact being particularly lightweight. In addition, because the fork contact can be designed to be relatively short in terms of its vertical direction, the dissipation of excess heat generated by the current flowing through the fork contact during operation can be carried out particularly effectively. As a result, even relatively high currents can be transmitted using the fork contact according to the invention.

[0016] When mechanically unloaded, the contact surfaces of the clamping areas are angled relative to the vertical direction of the fork contact such that, after insertion of the contact element, the contact surfaces run at least essentially parallel to the vertical direction of the fork contact. If, for example, the contact element to be contacted is a plug-in tongue with a rectangular contour, this helps ensure that the contact surfaces lie against the plug-in tongue over a particularly large area after insertion of the plug-in tongue. This reliably prevents the contact element in question from undesired sinking towards the base of the fork contact. Furthermore, this also ensures that the contact surfaces of the fork contact lie against the contact element in question over a particularly large area, which has a positive effect on the current-carrying capacity.The inclination of the contact surfaces of the clamping areas relative to the vertical direction of the fork contact is therefore selected to suit the respective contact element in such a way that after the contact element has been inserted into the fork contact, the contact legs are spread apart to such an extent that the contact surfaces run at least substantially parallel to the vertical direction of the fork contact and thus lie particularly reliably against the respective contact element over a large area.

[0017] A further advantageous embodiment of the invention provides that the clamping areas widen transversely above and below the contact surfaces. This creates a defined contact area for the contact surfaces. Furthermore, the widening of the clamping areas above the contact surfaces ensures particularly easy insertion of the contact element. The widening of the clamping areas below the contact surfaces also ensures that the inserted contact element no longer rests against the contact legs below the contact surfaces.

[0018] The clamping areas have a bulbous contour relative to the plane spanned by the vertical and transverse directions, preferably without losing the property of preventing sinking in the transverse and / or vertical directions. The clamping areas can, for example, resemble the bulbous area of ​​a "D." This makes it particularly easy to achieve a widening of the clamping areas above and below the contact surfaces in the transverse direction. Other contours or shapes of the clamping areas are, of course, also possible.

[0019] According to a further advantageous embodiment of the invention, the clamping areas have a recess on their rear side facing away from the respective contact surface. These recesses create a kind of extended spring area on the contact legs of the fork contact. The elastically resilient properties of the contact legs and the associated reliable mechanical and electrical contacting of the contact element by means of the fork contact can thus be further improved. Furthermore, the recess allows for material and thus weight savings in the fork contact.

[0020] In a further advantageous embodiment of the invention, the clamping areas have an at least substantially constant cross-section relative to the plane spanned by the vertical and transverse directions. This further improves the elastically resilient properties of the fork contact, or more precisely, the contact legs, upon insertion of the respective contact element.

[0021] A further advantageous embodiment of the invention provides for the fork contact to have several pairs of contact legs. It is thus possible to provide several pairs of these contact legs, with each pair of contact legs being responsible for accommodating a contact element. Depending on the application, the fork contact can thus be designed to accommodate a plurality of contact elements between the respective pairs of contact legs.

[0022] According to a further advantageous embodiment of the invention, the base of the fork contact is arranged at the same height, relative to the vertical direction of the fork contact, both between the contact legs and adjacent to them. This results in particularly advantageous elastic bending properties of the contact legs when the respective contact element is inserted into the fork contact. The contact legs are thus supported equally strongly or equally little from both sides by the remaining material of the fork contact around the base of the fork contact. As a result, a relatively uniform mechanical stress distribution results within the contact legs when the contact element is inserted and positioned between the clamping areas of the fork contact.

[0023] A further advantageous embodiment of the invention provides that the fork contact has at least one solder contact on a bottom side facing away from the contact legs. Of course, depending on the application, the fork contact can also have several such solder contacts on its bottom side. This allows the fork contact to be electrically connected to a circuit board or the like in a very simple manner.

[0024] In a method not claimed here for producing the fork contact according to the invention or an advantageous embodiment of the fork contact according to the invention, a geometric adaptation of the fork contact to a predetermined application can be achieved solely by adjusting the width of the contact gap. In other words, this method provides that, depending on the application and in particular depending on the contact element to be accommodated and the shape of the contact element, the manufacturing method is only adapted to the extent that the width of the contact gap of the fork contact, or in the case of several pairs of contact legs, the respective widths of the contact gaps, are adjusted accordingly. This results in a particularly simple method for producing a fork contact, since only the width of the contact gap needs to be adapted for the respective application of the fork contact.

[0025] An advantageous embodiment of this method provides for the adjustment of the width of the contact gap by adapting the arrangement of the contact legs relative to the transverse direction of the fork contact to the intended use. In other words, a kind of displacement of the contact legs occurs, either away from or toward each other, depending on the intended use and the contact element for which the fork contact is being manufactured.

[0026] According to a further advantageous embodiment of this method, the width of the contact gap is adjusted by adapting the respective contour of the contact surfaces of the clamping areas to the intended use. The clamping areas can, for example, be designed to be more or less bulbous, so that the width of the clamping gap can be easily varied. Regardless of how precisely the width of the contact gap is adjusted, the fork contact can be manufactured particularly cost-effectively and in large quantities, for example, by a stamping process. Other manufacturing processes are also possible and useful depending on the quantities.

[0027] Further advantages, features and details of the invention will become apparent from the following description of preferred embodiments and from the drawings. Character description

[0028] The drawing shows: Fig. 1 a front view of a first embodiment of a fork contact for electrically contacting a contact element, wherein the fork contact has a single pair of contact legs for receiving the contact element and respective clamping regions of the contact legs have a recess on their rear sides facing away from respective contact surfaces; Fig. 2 is a front view of a second embodiment of the fork contact, which differs from the first embodiment only in that the fork contact has two pairs of contact legs; Fig. 3 shows a front view of a third embodiment of a fork contact to explain the technical context, wherein this differs from the second embodiment with regard to the shape of the clamping areas in that they have no recess on their rear sides facing away from the respective contact surfaces; and in Fig. 4 is a front view of a fourth embodiment of the fork contact, which differs from the one shown in Fig. 2 in that the fork contact has several solder contacts on its underside.

[0029] In the figures, identical or functionally identical elements are provided with the same reference symbols.

[0030] A first embodiment of a fork contact 1 for electrically contacting a contact element (not shown) is shown in a front view in Fig. 1. The fork contact 1 comprises a single pair of contact legs 3 extending from a base 2 of the fork contact 1 in the vertical direction z of the fork contact 1. A contact gap 4 is located between the contact legs 3. By means of the fork contact 1, for example, a contact element in the form of a plug-in tongue or the like can be contacted by pushing the respective contact element into the contact gap 4. When the contact element is inserted into the contact gap 4, the fork contact 1 is elastically expanded in the transverse direction y of the fork contact 1.

[0031] This means that the contact legs 3 are elastically expanded outwards when the contact element is inserted into the contact gap 4, as shown in the illustration. The width of the contact gap 4 is selected such that, in the mechanically unloaded state, i.e. as long as the contact element has not yet been pushed into the contact gap 4, it is slightly smaller than the width of the contact element to be contacted. As a result, the inserted contact element is clamped between the respective contact surfaces 5 of the respective clamping regions 6 of the contact legs 3 in the transverse direction y of the fork contact 1. The contact surfaces 5 therefore lie more or less flat against the inserted contact element and thereby exert a normal force in the transverse direction y on the inserted contact element, as a result of which the contact element is clamped between the clamping regions 6 and is thus contacted both mechanically and electrically with the fork contact 1.

[0032] The contact legs 3 taper from the base 2 of the fork contact 1 to their clamping areas 6 relative to a plane spanned by the vertical direction z and the transverse direction y. The contact legs 3 essentially behave like clamped beams that are clamped in the area of ​​the base 2 of the fork contact 1. Because the contact legs 3 taper in the manner described, starting from the base 2 and reaching the clamping areas 6 relative to the plane spanned by the vertical direction z and the transverse direction y, the contact legs 3 have particularly good elastic spring properties, which have a positive effect on the mechanical and electrical contacting of the contact element to be accommodated.

[0033] As a result, the fork contact 1 can be designed to be particularly compact with respect to its vertical direction z. As a result, tolerances regarding the width of the contact gap 4 can also be kept relatively small. The fork contact 1 can be manufactured, for example, by stamping. Preferably, the fork contact 1 is made of a material with good electrical conductivity, such as copper. The overall shape of the fork contact 1 is configured such that, upon insertion of the contact element, the fork contact 1 allows for springing in the elastic range, as a result of which the contact element can be electrically and mechanically contacted particularly reliably.

[0034] In the mechanically unloaded state, the contact surfaces 5 of the clamping areas 6 are inclined relative to the vertical direction z of the fork contact 1 such that, after insertion of the contact element, the contact surfaces 5 run at least substantially parallel to the vertical direction z of the fork contact 1. In the present illustration, it is clearly visible that the contact surfaces 5 are slightly inclined relative to the vertical direction z as long as the contact element (not shown here) is not located in the contact gap 4.

[0035] The said inclination of the respective contact surfaces 5 relative to the vertical direction z of the fork contact 1 is selected such that, adapted to the width of the contact element to be inserted, the contact legs 3 are elastically spread or widened to such an extent that the contact surfaces 5 extend at least substantially parallel to the vertical direction z of the fork contact 1 when the contact element has been inserted into the contact gap 4. This is particularly useful if the contact element to be inserted has a rectangular cross-section with respect to the plane spanned by the vertical direction z and transverse direction y, as shown in the illustration.However, if the contact element does not have a rectangular cross-section with respect to this plane, the contact surfaces 5 can also be positioned relative to the vertical direction z of the fork contact 1 in the mechanically unloaded state in such a way that the contact surfaces 5, after insertion of the contact element, run parallel to the respective flanks of the contact element which are to bear against the contact surfaces 5.

[0036] As can be seen, the clamping areas 6 widen above and below the contact surfaces 5 in the transverse direction y. This allows the contact element to be inserted particularly easily from above into the contact gap 4, and it also clearly defines where the contact surfaces 5 end. In this case, the clamping areas 6 have a bulbous contour relative to the plane spanned by the vertical direction z and the transverse direction y. The clamping areas 6 are essentially D-shaped, with the contact surfaces 5 corresponding to the curved part of a "D."

[0037] In the present embodiment of the fork contact 1, the clamping regions 6 have a recess on their rear side 7 facing away from the respective contact surface 5. This promotes the elastic spring behavior of the contact legs 3 when the contact element is inserted into the contact gap 4. Furthermore, this allows material to be saved on the fork contact 1. For example, as in the present embodiment, it is also possible for the clamping regions 6 to have an at least substantially constant cross-section with respect to the plane spanned by the vertical direction z and the transverse direction y. Other cross-sectional configurations are of course also possible.

[0038] In Fig. Figure 2 shows a front view of a second embodiment of the fork contact 1. The fork contact 1 shown here differs from the first embodiment in that it has two pairs of contact legs 3. The actual structure of the contact legs 3 is the same as in the first embodiment. The fork contact 1 according to the second embodiment can therefore accommodate two contact elements, for example in the form of plug-in tongues or the like, by means of the four contact legs 3.

[0039] The base 2 of the fork contact 1 is arranged at the same height, relative to the vertical direction z of the fork contact 1, both between the respective contact legs 3 and beside them. Thus, based on the present illustration, the contact legs 3 are supported laterally from both the left and right sides to the same extent or to the same extent by the remaining material of the fork contact 1. This results in particularly favorable mechanical stress conditions during or after insertion of the respective contact elements into the respective contact gaps 4.

[0040] In Fig. Figure 3 shows a third embodiment of a fork contact 1 in a front view to explain the technical context. The third embodiment of the fork contact 1 differs from the second embodiment of the fork contact 1 only in that the clamping regions 6 do not have a recess on their rear side 7 facing away from the respective contact surface 5. In the third embodiment of the fork contact 1, the clamping regions 6 are therefore designed to be significantly thicker relative to the transverse direction y.

[0041] In Fig. 4, a fourth embodiment of the fork contact 1 is shown in a front view, wherein the fourth embodiment of the fork contact 1 differs from the one shown in Fig.2 only in that the fork contact 1 has four solder contacts 9 on a bottom side 8 facing away from the contact legs 3. The fork contact 1 can thus be inserted, for example, into a circuit board or the like and subsequently soldered to it.

[0042] The described fork contacts 1 are preferably manufactured by a stamping process. The geometric adaptation of the respective fork contact 1 to a given application, and in particular to a contact element to be contacted, is preferably achieved exclusively by adjusting the width of the respective contact gap 4.

[0043] This can be achieved, for example, by adjusting the distance between the contact legs 3 to suit the respective application and the contact element to be accommodated. In other words, the contact legs 3 are punched out or otherwise manufactured slightly further apart or slightly closer together, so that the width of the contact gap 4 is adjusted accordingly.

[0044] Alternatively or additionally, the width of the respective contact gap 4 can also be adjusted by adapting the respective contour of the contact surfaces 5 of the clamping areas 6 to the respective application and, in particular, to the respective contact element to be accommodated. For example, the clamping areas 6 can be designed to be slightly more or less bulbous relative to their respective contact surfaces 5, so that the width of the contact gap 4 is varied accordingly. LIST OF REFERENCE SYMBOLS 1 fork contact 2 Reason for fork contact 3 contact legs 4 Contact gap 5 Contact surface 6 Contact area 7 Back 8 Bottom 9 Solder contact y transverse direction z vertical direction

Claims

[1] Fork contact (1) for electrically contacting a contact element, comprising at least one pair of contact legs (3) extending from a base (2) of the fork contact (1) in the vertical direction (z) of the fork contact (1), between which a contact gap (4) exists and which, upon insertion of the contact element into the contact gap (4), are elastically expanded in the transverse direction (y) of the fork contact (1), thereby clamping the inserted contact element between respective contact surfaces (5) of respective clamping regions (6) of the contact legs (3) in the transverse direction (y) of the fork contact (1), wherein the contact legs (3) taper from the base (2) of the fork contact (1) to their clamping regions (6) relative to a plane spanned by the vertical direction (z) and transverse direction (y), wherein, in the mechanically unloaded state, the contact surfaces (5) of the clamping regions (6) are inclined relative to the vertical direction (z) of the fork contact (1),that the contact surfaces (5) run at least substantially parallel to the vertical direction (z) of the fork contact (1) after insertion of the contact element, , characterized by that the clamping areas (6) have a bulbous contour and an at least substantially unchanging cross-section with respect to the plane spanned by the vertical direction (z) and transverse direction (y). [2] Fork contact (1) according to claim 1, characterized by that the clamping areas (6) widen above and below the contact surfaces (5) in the transverse direction (y). [3] Fork contact (1) according to one of the preceding claims, characterized by that the clamping areas (6) have a recess on their rear side (7) facing away from the respective contact surface (5). [4] Fork contact (1) according to one of the preceding claims, characterized by that the fork contact (1) has several pairs of contact legs (3). [5] Fork contact (1) according to one of the preceding claims, characterized by that the base (2) of the fork contact (1) is arranged at the same height both between the contact legs (3) and next to them, relative to the vertical direction (z) of the fork contact (1). [6] Fork contact (1) according to one of the preceding claims, characterized by that the fork contact (1) has at least one solder contact (9) on an underside (8) facing away from the contact legs (3). [7] Fork contact (1) according to one of the preceding claims, characterized by that the fork contact (1) is manufactured by a punching process.

Images