Plug-in contact element and direct connector

Abstract

Plug-in contact element (1) for producing an electrical connection between two components, in particular between at least one component and a printed circuit board (6), wherein the plug-in contact element (1) is produced by stamping (12), characterized in that the plug-in contact element (1) has at least one pin element (3) and / or at least one socket element (4) for connection to at least one component and at least one plug element (5) for direct contacting a printed circuit board.

Description

[0001] The invention relates to a plug-in contact element for producing an electrical connection between two components, in particular between a component and a printed circuit board, wherein the plug-in contact element is produced by stamping.

[0002] Furthermore, the invention relates to a direct connector comprising at least one plug contact carrier, wherein at least one plug contact element according to the invention is arranged in the plug contact carrier and with a housing, wherein the at least one plug contact carrier is arranged in the housing.

[0003] Stamped contact metals are known from the prior art.

[0004] German publication DE 102 49 683 B4 discloses a contact element for electrically contacting a mating contact, comprising a contact section with two spring-elastic clamp arms for contacting the mating contact and a base section for connection to a printed circuit board. According to one embodiment, the contact element is a stamped sheet metal part.

[0005] Furthermore, a plug contact for connecting a conductor to a printed circuit board using direct plug technology with a mounting frame is known from the publication DE 20 2016 105 358 U1, wherein the plug contact is designed as a stamped and bent part.

[0006] Based on the prior art described above, the object of the invention is to provide a plug-in contact element that is particularly easy to manufacture and whose functionality is improved. Furthermore, the object of the invention is to provide a direct plug connector comprising at least one contact element according to the invention.

[0007] According to a first teaching of the present invention, the aforementioned problem is solved by a plug-in contact element mentioned above in that the plug-in contact element has at least one pin element and / or at least one socket element for connection to the components to be connected, and at least one plug element for direct contacting a printed circuit board.

[0008] According to the invention, it was recognized that a contact element suitable for direct plug-in technology can be designed as a purely stamped part, thereby avoiding costly bending process steps.

[0009] According to a further preferred embodiment, the plug contact element is post-processed by embossing in at least one contact area. The plastic deformation improves the surface quality and the cut edges resulting from the stamping process. Particularly preferably, the plug contact element is embossed in both the socket and pin areas, thus improving the electrical connection to the plug contact element.

[0010] According to an advantageous embodiment, the bushing element is tapered at least in some areas. This has the advantage that simple and precise calibration of the contact opening dimension is possible in the tapered area after stamping.

[0011] Another advantageous embodiment of the plug-in contact element is characterized by the fact that the pin element is widened, at least in sections, such that it is wider than the material thickness of the remaining part of the plug-in contact element. This has the advantage that, when connecting the pin element to a socket element, contact is more easily established due to the increased contact area. For example, the pin element can be widened by plastic deformation after stamping.

[0012] The plug contact element according to the invention is suitable for insertion into a plug contact carrier.

[0013] The system consisting of the plug contact carrier and the at least one plug contact element can also be designed according to one or more of the following embodiments within the scope of the present invention.

[0014] According to a further advantageous embodiment, the plug contact element has a connection area that connects the contact areas to one another. It is advantageous if the at least one plug contact element is fixed in a plug contact carrier by a snap-fit ​​connection, wherein the snap-fit ​​connection is arranged in the connection area of ​​the plug contact element.

[0015] According to this embodiment, the at least one plug-in contact element can be inserted into the plug-in contact carrier, specifically plugged in. The plug-in contact carrier and the at least one plug-in contact element are designed such that the at least one plug-in contact element is immediately secured by the locking mechanism after insertion. Because the locking mechanism is located in the connection area of ​​the plug-in contact element and thus not in the contact areas of the plug-in contact element, the locking mechanism has no effect on the contact areas and, in particular, not on the quality of the contacts. Even incomplete locking does not necessarily lead to a reduction in contact quality.

[0016] As a result, this system ensures, on the one hand, a particularly simple connection of the at least one plug contact element with the plug contact carrier and, on the other hand, improved contact with other components.

[0017] For example, the locking connection is designed as a rear locking mechanism. Rear locking means that the locking action in the insertion direction occurs behind a locking element or counter-locking element located on the connector carrier.

[0018] According to a preferred embodiment, the at least one plug contact element has a locking element, in particular in the form of a locking lug or a locking hook, and the plug contact carrier has a locking counterpart element, in particular in the form of a recess, wherein the locking element forms a locking connection with the locking counterpart element when the plug contact element is plugged in, and wherein the locking element is arranged in the connection area of ​​the at least one plug contact element.

[0019] It is also conceivable that the plug contact carrier has a locking element, in particular in the form of a locking lug or a locking hook, which, when plugged in, engages in a locking counter-element arranged on the at least one plug contact element, in particular in the form of a recess.

[0020] Particularly preferably, the locking element and the counter-locking element are designed such that the locking element is elastically deformed and / or deflected during insertion, preferably by the counter-locking element. In the inserted state, the locking element assumes its original shape or position, thereby creating a positive and / or force-fit locking connection.

[0021] According to a further preferred embodiment, the at least one plug contact element is fixed in the plug contact carrier by exactly one locking connection. In this embodiment, in addition to the locking connection, further defined contact areas, in particular in the form of stops and / or bearing surfaces and / or guide surfaces, are optionally provided between the at least one plug contact element and the plug contact carrier, wherein the defined contact areas stabilize the position of the plug contact element in the plug contact carrier.

[0022] A further advantageous embodiment is characterized in that the at least one plug-in contact element is designed such that, in the inserted state, defined contact areas, in particular in the form of stops and / or bearing surfaces and / or guide surfaces, are present with the plug-in contact carrier, as well as areas where a gap exists between the components. Such a gap can be created, for example, by at least partially thinning the plug-in contact element. In significant areas, such as the area of ​​the socket element and / or the pin element, the at least one plug-in contact element does not rest on the plug-in contact carrier. The defined contact areas with the plug-in contact carrier are particularly preferably arranged in the connection area of ​​the plug-in contact element.

[0023] Such a design has the advantage that manufacturing-related tolerances in the flatness of the plug contact element and / or the plug contact carrier have essentially no effect on the position of the plug contact element in the plug contact carrier.

[0024] According to a further embodiment, the plug contact element has at least two contact surfaces, preferably in the connection area, with which the plug contact element rests on the plug contact carrier. Preferably, the sum of the contact surfaces is less than 50%, less than 40%, or less than 30% of the total possible contact area.

[0025] Preferably, the plug contact element has exactly two contact surfaces with which it rests on the plug contact carrier. This design represents an optimal compromise between ensuring a stable position of the plug contact element within the plug contact carrier and providing sufficient clearance between the components to minimize the impact of manufacturing tolerances.

[0026] Particularly preferably, the connector carrier has at least one stop surface for positioning the at least one connector element in the insertion direction, wherein the connector element has at least one counter-stop surface, and wherein each counter-stop surface bears against a stop surface of the connector carrier when inserted. A defined number of stop surfaces ensures that the connector element is positioned precisely when inserted, and the stop surfaces particularly limit the movement of the connector element in the insertion direction. According to a particularly preferred embodiment, the connector carrier has at least two stop surfaces, wherein the connector element bears against the two stop surfaces with two counter-stop surfaces when inserted. In this way, particularly precise positioning of the connector element in the connector carrier can be ensured.

[0027] According to a particularly preferred embodiment, the at least one plug contact element is manufactured from a flat metallic material by stamping. A plug contact element manufactured in this way differs advantageously from stamped-bent contacts known from the prior art by a particularly simple manufacturing process. If a locking element is arranged on the plug contact element, this locking element can be formed directly during stamping.

[0028] The plug contact carrier is preferably made of plastic.

[0029] Furthermore, it is advantageous if the plug contact carrier has at least three guide elements, in particular in the form of guide surfaces, wherein the guide elements guide and / or stabilize the at least one plug contact element in three spatial directions during insertion and / or in the inserted state.

[0030] According to a particularly preferred embodiment, the plug contact carrier has at least one guide element, preferably in the form of a guide rail, wherein the guide element extends in the insertion direction and wherein, to connect the components, the plug contact element is inserted into the plug contact carrier along the guide element.

[0031] If the connector carrier has a plurality of connector elements, a guide element, preferably in the form of a guide rail, is arranged on the connector carrier for each connector element. It is further advantageous if the guide element extends on two sides of the connector element in the insertion direction, so that straight insertion of the connector element into the connector carrier can be ensured.

[0032] According to a further embodiment, the guide element is designed as a guide housing, the guide housing extending along three sides of the plug contact element in the insertion direction. This design ensures particularly precise positioning of the plug contact element even during insertion.

[0033] According to a particularly preferred embodiment, the guide housing has a recess into which the locking element of the plug contact element engages when inserted. In this embodiment, the recess of the guide housing acts as a locking counter-element.

[0034] According to a second teaching of the present invention, the problem set out at the outset is solved by a direct connector comprising at least one plug contact carrier, wherein at least one plug contact element according to one of the previously described embodiments is arranged in the plug contact carrier and with a housing, wherein the at least one plug contact carrier is arranged in the housing.

[0035] In addition, the direct connector can alternatively or additionally be designed according to one of the following configurations.

[0036] According to a preferred embodiment, the direct connector has a housing, the housing comprising a receiving area, wherein the receiving area has at least two, preferably lateral, boundaries, the at least two boundaries of the receiving area securing the connector carrier by positive and / or frictional locking. Particularly preferably, the boundaries extend in the insertion direction of the connector carrier, so that a fixation extending over the entire receiving area can be ensured. For example, the boundaries are designed as boundary walls or boundary edges. Particularly preferably, the at least two boundaries are designed as opposing side walls.

[0037] This ensures that the plug-in contact elements intended for connection, which are arranged in the plug-in contact carrier, can be positioned particularly advantageously in the housing by inserting the plug-in contact carrier into the receiving area of ​​the housing, and that, in the inserted state, the plug-in contact carrier is fixed by the receiving area in a form-fit and / or force-fit manner. In this way, a stable positioning of the plug-in contact elements intended for connection is also achieved.

[0038] According to a further advantageous embodiment, the plug contact carrier and the receiving area of ​​the housing are designed such that the plug contact carrier can be inserted into the receiving area and that during insertion there is initially a clearance fit and only when the plug contact carrier is fully inserted is it fixed by an interference fit.

[0039] The interference fit is particularly preferably achieved in the inserted state by means of a transition fit or an interference fit.

[0040] According to a further embodiment, the plug contact carrier is positioned and / or fixed in the inserted state by at least two press fits, wherein preferably one press fit is realized in the rear area of ​​the plug contact carrier in the insertion direction and wherein a second press fit is realized in the front area of ​​the plug contact carrier in the insertion direction.

[0041] A press fit can preferably be achieved by ensuring that, in the unconnected state, the distance between the side walls or side edges of the plug contact carrier is at least partially greater than the distance between the lateral boundaries of the receiving area.

[0042] According to a further advantageous embodiment, the lateral boundaries of the receiving area of ​​the housing and / or the side walls or the side edges of the plug contact carrier are not aligned parallel to each other, at least in some areas, but the distance between the lateral boundaries of the receiving area and / or the distance between the side walls or the side edges of the plug contact carrier decreases in the insertion direction of the plug contact carrier.

[0043] According to a further embodiment, an interference fit can also be achieved or improved by ensuring that at least one lateral boundary of the receiving area is not parallel to the adjacent side wall or side edge of the connector carrier. The angle to the respective adjacent side wall or side edge is preferably in the range of 0.5 to 10°, more preferably in the range of 0.5 to 5°, and particularly preferably in the range of 0.5 to 2°.

[0044] A press fit can also be achieved or improved by ensuring that at least one side wall or edge of the connector carrier is not parallel to the adjacent lateral boundary of the receiving area. The angle to the respective adjacent lateral boundary is preferably in the range of 0.5 to 10°, more preferably in the range of 0.5 to 5°, and particularly preferably in the range of 0.5 to 2°.

[0045] An interference fit can alternatively or additionally be achieved by having at least one lateral boundary of the receiving area and / or at least one side wall or side edge of the plug contact carrier have at least one step.

[0046] According to a particularly preferred embodiment, in the connected state an interference fit is achieved by two opposing steps of the lateral boundary of the receiving area and a second interference fit is achieved by two opposing steps in the side walls or the side edges of the plug contact carrier.

[0047] Another embodiment of the direct connector is characterized by the fact that the receiving area has at least three boundaries, such that the boundaries enclose the connector carrier on at least three sides. Particularly preferably, the boundaries are arranged such that they limit the movement of the connector carrier both laterally and in the insertion direction, thereby positively positioning the inserted connector carrier on at least three sides.

[0048] According to a further embodiment, the receiving area has at least four boundaries for positioning and fixing the plug contact carrier, which are arranged in such a way that they position and / or fix the plug contact carrier both laterally and in the insertion direction as well as opposite the connection to the circuit board.

[0049] A particularly preferred feature is a base opposite the printed circuit board to be plugged in. The forces acting when plugging in the printed circuit board can be absorbed by the base, thereby relieving the stress on the plug-in contact elements.

[0050] Furthermore, it is preferred if the housing has a lateral opening in the receiving area, wherein a lateral opening is oriented essentially perpendicular to the insertion direction of the printed circuit board to be connected.

[0051] To improve the fixation of the connector carrier in the housing, it is further advantageous if the connector carrier, preferably in the area of ​​the side walls, has at least one locking element, for example in the form of a locking lug or a locking hook, wherein the at least one locking element, when inserted, engages in a corresponding locking element, for example in the form of a recess, wherein the corresponding locking element is preferably arranged in the area of ​​a lateral boundary of the receiving area of ​​the housing. Particularly preferably, the at least one locking element is arranged and designed such that it projects beyond the side wall or side edge of the connector carrier. Particularly preferably, the locking element is deflected and / or deformed elastically during the insertion process, whereby the locking element engages in its original shape and / or position in the corresponding locking element.

[0052] For example, the locking element can be designed as a recess in the lateral boundary of the receiving area, with the locking element snapping into the recess when inserted. Alternatively, the lateral boundary of the receiving area can also exhibit a discontinuous or continuous change in the distance between the boundaries.

[0053] The plug connector element is manufactured by stamping.

[0054] Optionally, after stamping the plug contact element, the contact areas of the plug contact element are embossed to improve the quality of the surface and / or the cut edges.

[0055] According to a further advantageous embodiment, the plug contact element is tapered, at least partially, in the area of ​​the socket element, particularly preferably in the front part of the socket element. This tapering can be achieved during the stamping process or subsequently. Subsequent adjustment of the contact opening dimension by plastic deformation can be implemented particularly easily in the tapered area.

[0056] The contact opening dimension of the bushing element, especially in the area of ​​the taper, can be calibrated after stamping by plastic deformation.

[0057] It is particularly preferred that, during stamping, the contact area of ​​the bushing element and / or the pin element is initially made wider, so that plastic deformation of these areas to the desired final dimension is possible while improving the surface quality.

[0058] To improve the quality of the cut edges, the cut edges of the contact areas are flattened at least partially after punching, according to a further embodiment.

[0059] Preferably, the pin element is widened, at least in some areas, by plastic deformation, so that contact with the pin element is improved by a particularly wide available surface. The pin element is preferably widened such that the set width is greater than the material thickness of the rest of the plug contact element.

[0060] A method for manufacturing a direct connector with a housing and a plug contact carrier according to one of the previous embodiments, wherein the housing has a receiving area for the plug contact carrier, may comprise the following process steps: - Production of at least one plug contact element by stamping a flat metallic material, - Inserting the at least one plug contact element into the plug contact carrier, wherein preferably the at least one plug contact element is fixed in its position immediately after insertion by a snap-fit ​​connection in a form-fit and / or force-fit manner, - Inserting the plug contact carrier, which has at least one plug contact element, into the receiving area of ​​the housing, wherein preferably the plug contact carrier is fixed in its position by positive locking and / or force locking immediately after insertion.

[0061] The method is particularly suitable for manufacturing a direct connector according to one of the above embodiments.

[0062] Furthermore, the plug contact element is preferably manufactured according to one of the methods described above.

[0063] In detail, there are numerous possibilities for designing and further developing the inventive plug-in contact element, the inventive direct connector, and the inventive methods. Reference is made to both the claims subordinate to the independent claims and to the following description of preferred embodiments in conjunction with the drawing. The drawing shows Fig. 1 a first embodiment of a plug contact element, Fig. 2 a plug contact carrier together with three exemplary embodiments of plug contact elements, Fig. 3 an embodiment of a direct connector, Fig. 4 An embodiment of a direct connector in its assembled state, Fig. 5 an embodiment of a method for manufacturing a plug contact element and Fig. 6 An embodiment of a method for manufacturing a direct connector.

[0064] In Fig. Figure 1 shows a first embodiment of a plug contact element 1 for use in a direct connector 2. The plug contact element 1 has a pin element 3, a socket element 4 and a plug element 5 for direct contacting a printed circuit board 6.

[0065] The illustrated plug contact element 1 is manufactured by stamping. The socket element 4 is tapered at the front 15. This has the advantage that, after stamping, the contact opening dimension can be precisely and easily adjusted by plastically deforming the tapered section 15. Furthermore, the pin element 3 is widened by embossing this area, so that the width of the pin element 3 is greater than the material thickness of the rest of the plug contact element 1. In addition, the cut edges of the pin element 1 are flattened. This improves the quality of the surface and the cut edges, and also ensures improved contact engagement when the pin element 3 is connected.

[0066] Fig. Figure 2 shows a plug connector carrier 7 together with three embodiments of plug connector elements 1. The plug connector elements 1 and the plug connector carrier 7 are designed such that the plug connector elements 1 can be inserted into the plug connector carrier 7 and that, after insertion, the plug connector elements 1 are fixed in their position by a locking connection. For this purpose, each plug connector element 1 has a locking element 9 which, when inserted, engages in a locking counter element 10 arranged on the plug connector carrier 7.

[0067] In Fig. Figure 3 shows an embodiment of a direct connector 2, wherein the direct connector 2 comprises a contact carrier 7 in which three contact elements 1 are arranged, and a housing, the housing having a receiving area 8 for the contact carrier 7. The contact carrier 7 and the receiving area 8 are designed such that the contact carrier 7 can be inserted into the receiving area 8, wherein during insertion there is initially a clearance fit between the components, which facilitates the insertion of the contact carrier 7, and wherein the contact carrier 7 is fixed in the inserted state by an interference fit. In the illustrated embodiment, the interference fit is realized by an interference fit in the rear and front areas of the contact carrier in the insertion direction.

[0068] A compound direct connector 2 is in Fig. 4 together with a circuit board 6 to be connected.

[0069] The circuit board 6 can be plugged onto the housing or onto the plug-in contact elements 1 to establish a contact. For this purpose, the circuit board 6 has corresponding contact holes.

[0070] The direct connector 2 shown is characterized by a particularly simple manufacturing of the plug contact elements as well as the improved quality of a connection via the contact areas of the plug contact element.

[0071] Fig. Figure 5 shows an embodiment of a method 16 for manufacturing a plug contact element 1, wherein the plug contact element 1 is manufactured according to the method described in Figure 5. Fig. 1 is designed as shown in the illustrated embodiment.

[0072] Procedure 16 comprises the following steps: - Stamping 12 of the plug contact element 1 from a metallic flat material, - Widening 17 of the pin element 3, - Flattening 18 of the cutting edges of the pin element 3 and - Calibration 19 of the contact opening dimension of the bushing element 4.

[0073] A plug contact element 1 produced in this way is characterized in particular by the fact that it is particularly easy to manufacture, while at the same time ensuring a high quality of the contact areas.

[0074] In Fig. Figure 6 shows a method 11 for manufacturing a direct connector 2, wherein the direct connector 2 is designed according to the one described in Figure 6. Fig. 3 is designed as shown in the exemplary embodiment.

[0075] Procedure 11 comprises the following steps: - Production of at least one plug contact element 1 by stamping 12 of a metallic flat material, - Inserting 13 of the at least one plug contact element 1 into the plug contact carrier 2, wherein the at least one plug contact element 1 is fixed in its position immediately after insertion by a snap-fit ​​connection in a form-fit and / or force-fit manner, - Inserting 14 of the plug contact carrier 2, which has at least one plug contact element 1, into the receiving area 8 of the housing, wherein the plug contact carrier 2 is fixed in its position immediately after insertion by positive locking and / or force locking.

[0076] Optionally, the plug contact element 1 can be configured according to the instructions in Fig. The process described in 5 can be manufactured using method 16, thereby achieving a qualitative improvement in the contacting areas 3 and 4. Reference sign 1 plug connector element 2 direct connectors 3 pin element 4 bushing element 5 connector element 6 circuit board 7 Plug connector carriers 8 Recording area 9 locking element 10 Latching counter element 11 Methods for manufacturing a direct connector 12 punches of the plug contact element 13. Inserting the plug contact element 14 Inserting the plug contact carrier 15 Rejuvenation 16 Methods for manufacturing a plug contact element 17 Widening of the pin element by plastic deformation 18. Flattening of the cut edges 19 Calibration of the contact opening dimension of the bushing element QUOTES INCLUDED IN THE DESCRIPTION

[0000] This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions. Cited patent literature

[0000] DE 102 49 683 B4

[0004] DE 20 2016 105 358 U1

[0005]

Claims

Plug-in contact element (1) for producing an electrical connection between two components, in particular between at least one component and a printed circuit board (6), wherein the plug-in contact element (1) is produced by stamping (12), characterized in that the plug-in contact element (1) has at least one pin element (3) and / or at least one socket element (4) for connection to at least one component and at least one plug element (5) for direct contacting a printed circuit board. Plug contact element (1) according to claim 1, characterized in that the plug contact element (1) is post-processed by embossing in at least one contacting area (3, 4, 5). Plug contact element (1) according to claim 1 or 2, characterized in that the socket element (4) is tapered at least in some areas. Plug contact element (1) according to one of claims 1 to 3, characterized in that the pin element (3) is widened at least in certain areas such that the pin element (3) is wider than the material thickness of the remaining part of the plug contact element (1). Direct connector (2) comprising at least one plug contact carrier (7), wherein at least one plug contact element (1) is located in the plug contact carrier (7) and with a housing, wherein the housing has a receiving area (8) and wherein the at least one plug contact carrier (7) is arranged in the receiving area (8) of the housing, wherein the plug contact element (1) is produced by stamping (12), characterized in that the plug contact element (1) has at least one pin element (3) and / or at least one socket element (4) for connection to at least one component and at least one plug element (5) for direct contacting a printed circuit board. Direct connector (2) according to claim 4, characterized in that the plug contact element (1) is designed according to one of claims 2 to 4.

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