Contact arrangement with busbar contact connection

Abstract

A contact arrangement (1) for detachable, electrically conductive contacting comprising a contact socket (10) and a contact holder (20) produced from a tubular semi-finished product by forming, wherein the contact socket (10) is inserted at least partially in the axial direction of the contact holder (20) into a contact holder receiving space (21) of the contact holder (20), wherein the contact holder (20) has a busbar contact connection (30) which is formed integrally with the contact holder receiving space (21) of the contact holder (20), characterized in that the busbar contact connection (30) is formed by compressing the tubular semi-finished product and the inner wall of the tube lie flat against each other on a bearing surface (32) and furthermore the contact holder receiving space (21) is designed as a blind hole into which a touch protection pin (12) with a touch protection pin carrier (13) is inserted.

Description

[0001] The invention relates to a contact arrangement for detachable, electrically conductive contacting, comprising a contact socket and a contact holder, wherein the contact socket is inserted at least partially in the axial direction of the contact holder into a contact holder receiving space.

[0002] For contacting or creating detachable, electrically conductive connections, plug connectors, contact elements, pole connectors, sockets, etc., are used in a wide variety of designs and variants. Particularly, but not exclusively, for electrical contacting tasks in the higher power range, contact systems have been developed that are based on circular contact geometries for receiving a contact pin and whose starting material consists of a planar contact grid that is hyperbolically twisted into the circular contact geometry. These contact systems, known as RADSOK, are characterized by robust and high-density contact formation due to the considerable contact area with the respective contact pin. Alternatively, instead of the hyperbolic twisting, inwardly directed lamellar geometries are known, whose lamellar contact grid is radially symmetrical.

[0003] These contact geometries, preferably used as high-current contact sockets, are therefore known as radial contact sockets or hyperbolic contact sockets.

[0004] RADSOK contact systems of the aforementioned type are received into connector socket sleeves via their generally cylindrical outer contours and achieve external contact via the cylindrical surfaces. DE 10 2007 051 266 B4 is based on the fundamental idea of ​​providing a single connector socket sleeve designed to accommodate different lamellar contact cages in the form of RADSOK contact sockets, which make contact with the inside of the contact sleeve.

[0005] A comparable basic structure is shown in DE 20 2016 100 095 U1. The subject matter of the invention here is the coupling, connection, and contacting of the cylindrical lamellar cage "floating" within the receiving connector socket sleeve by fixing only one of the respective end flanges in the socket, for example, by press fit. An electrical connector socket is provided, comprising a cylindrical socket sleeve, which is designed with a receiving space in which a cylindrical lamellar cage with a plurality of parallel contact lamellae is inserted, wherein the lamellar cage has a first and second end-end circumferential flange between which the contact lamellae extend.The lamellar cage is fixed at one end, at least axially and preferably also rotationally fixed, in the bushing sleeve, thereby clamping or securing it. At the opposite end, an axial sliding bearing, rotatable at least through a certain angle, is provided relative to the bushing sleeve. Preferably, the lamellar cage is fastened to the inner wall of the bushing sleeve by means of a sleeve-side fastening element via a flange.

[0006] From DE 10 2011 105 821 B4, an electrical connector socket is known with a cylindrical socket sleeve, wherein the socket sleeve has a receiving space in which a hyperbolically twisted lamellar cage is mounted, the socket sleeve has a first and second end face, and the lamellar cage is positively connected to the socket sleeve by means of connecting tongues on the first and second end faces. In the transition area between the socket sleeve and the connecting tongue, openings are provided such that at least one of the connecting tongues of the lamellar cage projects through one of the openings.

[0007] Different designs for contact sockets are known from the documents US 2015 / 0024641 A1, EP 3 570 382 A1, WO 2022 / 040636 A1 and CN 108011222 A.

[0008] In practice, contact holders are frequently used to accommodate, connect, and mount contact sockets, including radial contact sockets. These contact holders accommodate the radial contact socket, at least partially, within an interior space compatible with the socket and typically feature a cable connection in the form of cross-head terminals, tubular terminals, or crimp connectors. Common contact holders are manufactured from a semi-finished material using material-removing processes—such as turning or milling—and are equipped with a screw mount. This solution is not only expensive and complex but also unsuitable for mass production and inflexible with regard to different applications.

[0009] The object of the invention is to further develop existing contact solutions with contact sockets and to at least partially reduce the existing disadvantages.

[0010] To solve the problem, the invention proposes a contact arrangement according to claim 1. Such a contact arrangement comprises a contact socket that is at least partially received in a receiving space of a contact holder with a busbar contact connection. The busbar contact connection is formed by a largely flat, elongated, or rail-shaped area, optionally with one or more mounting holes. The busbar contact connection of the contact holder is particularly well-suited for high-voltage applications, and the same generally applies to the contact socket, so that the proposed contact arrangement offers particular advantages for high-voltage applications.

[0011] The contact socket (other common names: RADSOK contact, radial contact socket, lamellar contact socket) has, according to the invention, an integrated touch protection, for example a centrally arranged touch protection pin.

[0012] According to the invention, the contact holder is to be manufactured by forming. Two different variants are proposed: In forming variant 1, the contact holder is formed from flat material, which can be pre-dimensioned by stamping. In forming variant 2, the contact holder is formed from tubular material. This means that the starting material for the contact holder is either tubular or flat.

[0013] In both forming variants, the contact holder, consisting essentially of the contact holder area with a receiving space for the contact socket and the busbar area, is designed to be formed in one piece. Alternatively, forming variant 1, based on flat material in the circumferential direction of the contact holder area, can be manufactured in at least two parts. Since the contact holder is tubular in its contact holder area and flat in its busbar area, the transition area between the two areas is subjected to particularly strong deformation during forming. Therefore, materials must be used that exhibit both good electrical conductivity and suitable formability.

[0014] The invention is explained in more detail below with reference to exemplary embodiments in conjunction with the figures. These show: Fig. 1 the perspective view of the contact arrangement with contact socket and contact holder in a first design variant; Fig. 2 the sectional side view of the contact arrangement with contact socket and contact holder; Fig. 3 the perspective view of the contact holder; Fig. 4 showing a center offset in the perspective view of the contact holder; Fig. 5 the sectional side view of the contact holder; Fig. 6 the perspective view of the contact arrangement with contact socket and contact holder in a further design variant; Fig. 7 the sectional side view of the contact arrangement with contact socket and contact holder in the design variant according to Fig. 6; Fig. 8 the perspective view of the contact holder in the design variant according to Fig. 6 and Fig. 7; Fig. 9 the sectional side view of the contact holder in the design variant according to Fig. 6, Fig. 7 and Fig. 8.

[0015] Fig. Figure 1 shows a perspective view of the contact arrangement 1 with contact socket 10 and contact holder 20 in a first embodiment. The current flow, and thus the electrically conductive contact, takes place between the contact lamellae 11 of the contact socket and the busbar contact terminal 30. For this purpose, the contact socket 10 is electrically coupled to the contact holder 20. For this coupling, the contact holder 20 has a contact holder receiving space 21 into which the contact socket 10 is at least partially inserted axially. To secure the contact socket 10 against decoupling, it can be fixed within the contact holder receiving space 21, for example, by pressing, gluing, or welding.

[0016] The contact holder 20 of the in Fig. The contact arrangement 1 shown in Figure 1 is manufactured according to the invention on a tubular semi-finished product by forming, such that the contact holder 20 is formed in one piece and the contact holder receiving chamber 21 is formed by a cylindrical section closed in the circumferential direction. The forming process can be carried out by hot or cold forming. While the tubular starting material undergoes no or only slight forming in the area of ​​the contact holder receiving chamber 21, the forming rate is considerable in the transition area between the contact holder receiving chamber 21 and the busbar contact connection 30.

[0017] Fig. Figure 2 includes the sectional side view of the contact arrangement 1 with contact socket 10 and contact holder 20. The contact socket 10 is at least partially, in some areas, inserted into the contact holder receiving space 21 of the contact holder 20.

[0018] In this embodiment, the contact bushing 10 is inserted axially into the contact holder receiving space 21 to approximately 30% of its total axial length, such that approximately 70% of the axial length of the contact bushing 10 projects beyond the contact holder receiving space 21. Depending on the application and the axial length of the contact bushing 10, the ratio of inserted length to projecting length of the contact bushing 10 in the axial direction can also be selected differently, for example 1:1, 1:2, 3:4. In all embodiments, it is advantageous to insert the contact bushing 10 completely into the existing contact holder receiving space 21 and thus extend the contact bushing 10 to the axial base of the contact holder receiving space 21.

[0019] Is the contact socket 10, as in Fig. As shown in Figure 2, optionally equipped with a touch protection pin 12 comprising a touch protection pin centering element formed by a one-sided, cylindrical touch protection pin carrier 13, it is necessary to insert this before inserting the contact socket 10 into the blind hole base of the contact holder receiving space 21. This allows the insertion length ratios of the contact socket 10 into the contact holder receiving space 21 to be reduced.

[0020] The tubular starting material of the contact holder 20 is primarily deformed in the transition area between the contact holder receiving chamber 21 and the busbar contact connection 30. The same applies to the busbar contact connection 30, where the tubular starting material is practically flattened and the former inner tube walls lie flat against each other, forming a contact surface 32. If, as shown in this embodiment, the center line xx is axially aligned in both the contact holder receiving chamber 21 and the busbar contact connection 30, then the contact surface 32 is located on the center line xx.

[0021] Fig. Figure 3 illustrates the perspective view of the contact holder 20 as a single component of the contact assembly 1. Fig. 2. Since this embodiment is based on a reshaped, formerly tubular semi-finished product, it is formed in one piece, and the contact holder receiving chamber 21 is formed by a circumferentially closed cylindrical section. The busbar contact connection 30 can have one or more mounting holes 31, allowing it to be fixed to a contacting partner, for example, a contact rail.

[0022] Fig. Figure 4 shows a perspective view of the contact holder 20 in a further embodiment variant, featuring a center offset. The axial center lines in the areas of the contact holder receiving space 21 and the busbar contact connection 30 are not aligned with each other, but are parallel to each other with a coaxial offset, so that the contact holder 20 has a center offset line yy.

[0023] Fig. Figure 5 shows the sectional side view of the contact holder 20 of the exemplary embodiment. Fig. 3 with axially aligned center line xx both in the area of ​​the contact holder receiving space 21 and in the area of ​​the busbar contact connection 30.

[0024] Fig. Figure 6 shows a perspective view of the contact arrangement 1 with contact socket 10 and contact holder 20 in a further embodiment variant. Analogous to the embodiment variants according to the Fig. 1, Fig. 2, Fig. 3, Fig. 4 to Fig. Here too, the current flow and thus the electrically conductive contact between the contact lamellae 11 of the contact socket and the busbar contact terminal 30 is realized. For this purpose, the contact socket 10 is electrically coupled to the contact holder 20 within a contact holder receiving space 21.

[0025] The contact holder 20 of the in Fig. The contact arrangement 1 shown in Figure 6 is produced according to the invention on a flat semi-finished product based on forming, such that the contact holder 20 is formed in one piece and the contact holder receiving space 21 is formed with at least one butt 22 preferably lying transversely to the circumferential direction.

[0026] The thrust 22 effectively "opens" the tubular, cylindrically shaped contact holder receiving space 21 and allows the inner diameter of the contact holder receiving space 21 to expand elastically. This can be used for clamping the contact socket 10 and, if applicable, the touch protection pin carrier 13 instead of or in addition to pressing, gluing, or welding to secure the contact socket 10 and, if applicable, the touch protection pin carrier 13 in the contact holder receiving space 21.

[0027] The forming process can be accomplished by hot or cold forming. While the planar starting material in the area of ​​the busbar contact connection 30 undergoes no or only slight forming, the forming rate in the transition area between contact holder receiving space 21 and the contact holder receiving space 21 is considerable.

[0028] Fig. Figure 7 shows the sectional side view of the contact arrangement 1 with contact socket 10 and contact holder 20 in the design variant according to Fig. 6. Due to the use of a flat semi-finished product as the starting material for the forming process for the contact holder 20 of this embodiment, it is optionally possible – and in the embodiment of the Fig. 7. One or more stop lugs 23 can be formed. This at least one stop lug 23 limits the axial insertion path of the contact socket 10 and, optionally, the touch protection pin carrier 13 into the contact holder receiving space 21. The at least one stop lug 23 is functionally a solid stop and thus mechanically limits the insertion path. At the same time, an exact axial positioning relative to the contact holder receiving space 21 is achieved for the contact socket 10 and, optionally, the touch protection pin carrier 13.

[0029] Fig. Figure 8 shows the perspective view of the contact holder 20 in the design variant according to Fig. 6 and Fig. 7, that is, produced on the basis of a flat semi-finished product by forming and thereby having at least one butt 22 and optionally at least one stop nose 23.

[0030] Fig. Figure 9 includes the sectional side view of the contact holder 20 in the design variant according to Fig. 6, Fig. 7 and Fig. 8. In this embodiment variant as well, a contact surface 32 is formed in the area of ​​the busbar contact connection 30, here formed by placing partial areas of the flat semi-finished product on top of each other. Reference symbol list 1 Contact arrangement 10 Contact socket 11 Contact strip 12 touch protection pins 13 touch protection pin carriers 20 contact holders 21 Contact holder receiving area 22 thrust 23 Stop nose 30 Busbar contact connector 31 Mounting hole 32 contact surface xx center line yy Center offset line

Claims

[1] Contact arrangement (1) for detachable, electrically conductive contacting comprising a contact socket (10) and a contact holder (20) produced from a tubular semi-finished product by forming, wherein the contact socket (10) is inserted at least partially in the axial direction of the contact holder (20) into a contact holder receiving space (21) of the contact holder (20), wherein the contact holder (20) has a busbar contact connection (30) which is formed integrally with the contact holder receiving space (21) of the contact holder (20), characterized by , that the busbar contact connection (30) is formed by compressing the tubular semi-finished product and the inner wall of the tube lies flat against a support surface (32) and furthermore the contact holder receiving space (21) is designed as a blind hole into which a touch protection pin (12) with a touch protection pin carrier (13) is inserted. [2] Contact arrangement (1) according to claim 1, characterized by, that the contact holder receiving space (21) is formed by a cylindrical section closed in the circumferential direction. [3] Contact arrangement (1) according to claim 1, characterized by , that the contact holder (20) is formed by forming a flat starting material, semi-finished product. [4] Contact arrangement (1) according to claim 3, characterized by , that the contact holder receiving space (21) has a buttress (22) lying transversely to the circumferential direction. [5] Contact arrangement (1) according to claim 3, characterized by that the contact holder receiving space (21) has at least one stop lug (23). [6] Contact arrangement (1) according to claim 1, characterized by , that the contact holder receiving space (21) and the busbar contact connection (30) of the contact holder (20) are formed in one piece. [7] Contact arrangement (1) according to claim 1, characterized by , that the contact holder (20) has an aligned center line xx or a center offset line yy. [8] Contact arrangement (1) according to claim 1, characterized by that the busbar contact terminal (30) has at least one mounting hole (31). [9] Contact arrangement (1) according to claim 1, characterized by , that the busbar contact connection (30) has a contact surface (32).

Images