Electrical contact element, electrical connector and electrical system

Abstract

Electrical contact element (1) for stripping-free connection to a cable (4) formed with an insulating covering (41, 43), in which at least one electrical conductor (40) is arranged inside the insulating covering (41, 43), with the following features: a) the contact element (1) has an electrically conductive fork contact (2) with two fork arms (21) spaced apart from each other by a gap (22), b) the contact element (1) is designed to receive and electrically contact the electrical conductor (40) in the space (22) between the fork arms (21), c) the contact element (1) has an insulating element (3) on each of the two fork arms (21), by which the fork arms (21) are electrically insulated at least on the sides (24) facing away from each other.

Description

[0001] The invention relates to an electrical contact element for stripping-free connection to a cable with an insulating sheath, in which at least one electrical conductor is arranged within the insulating sheath. The invention further relates to an electrical connector with at least one such electrical contact element and an electrical system comprising an electrical connector and a multi-pole cable with an insulating sheath.

[0002] Electrical contact elements for stripping-free connection to cables with insulating sheaths are known, e.g., as so-called insulation displacement contacts (IDCs). With such a contact element, the electrical conductor located inside the insulating sheath can be directly electrically contacted without the need for a separate stripping process in which a portion of the insulating sheath is removed from the electrical conductor. Instead, such a contact element can be pressed directly onto the cable, automatically cutting the insulating sheath and contacting the inner electrical conductor. Stripping-free connection refers to such a connection process in which no separate stripping process is required beforehand.

[0003] The invention is based on the objective of providing an electrical contact element that enables reliable electrical contact during stripping-free connection and is universally applicable to all possible cable types. Furthermore, an electrical connector with such a contact element and an electrical system with such an electrical connector are to be provided.

[0004] This task is solved by an electrical contact element of the type mentioned above, which has the following characteristics: a) the contact element has an electrically conductive fork contact with two fork arms spaced apart from each other by a gap, b) the contact element is designed to receive and electrically contact the electrical conductor in the space between the fork arms, c) The contact element has an insulating element on each of the two fork arms, by which the fork arms are electrically insulated at least on the sides facing away from each other.

[0005] Such a contact element enables reliable and targeted electrical contact of the electrical conductor located within the insulation sheath. This is achieved by gripping the conductor in the space between the fork arms and making electrical contact there. Additionally, the insulating elements on the fork arms ensure isolation from the environment, particularly in the immediate vicinity of the fork arms, preventing unwanted contact with adjacent electrical conductors or other electrically conductive parts of the cable. The electrical contact element can be connected to the cable like an insulation displacement connector by simply pressing it through the insulation sheath until the desired electrical conductor is gripped and electrically contacted in the space between the fork arms.

[0006] In particular, the contact element according to the invention is also suitable for direct, stripping-free connection to a cable in which a shield is present surrounding the electrical conductor(s), i.e., a layer of an electrically conductive material that serves to shield the internal electrical conductor(s) from the environment. Such a shield can, for example, be designed as a metal braid, as is known from antenna cables. The insulating elements also protect the fork arms from unwanted electrical contact with the shield, especially after penetrating the insulation sheath and the shield.

[0007] The respective insulating element can be in direct contact with the associated fork arm or separated from it by a small gap. This close proximity of the insulating element to the associated fork arm reliably prevents unwanted short circuits to adjacent conductors or the shielding. The fork contact can have a main body from which the fork arms extend essentially parallel to each other, forming the space between the fork arms.

[0008] The fork arms can be designed, for example, like fork tines. The fork arms can be electrically insulated by the associated insulating element, at least in the area where the electrical conductor between the fork arms makes electrical contact. The insulating element can also extend into adjacent areas of this contact zone or over the entire length of the respective fork arm.

[0009] According to an advantageous embodiment of the invention, the side of each fork arm facing the gap is connected to the side facing away from the gap via at least one side surface, wherein at least one insulating element associated with the respective fork arm also provides at least partial electrical insulation to one or two opposing side surfaces of the fork arm. In this way, the insulating element also provides additional lateral insulation to the respective fork arm. The insulating element can, for example, be angled in profile or U-shaped. This further improves the protective effect of the insulating element with respect to adjacent electrical components such as the shielding.

[0010] According to an advantageous embodiment of the invention, the contact element is designed to penetrate the cable's shielding, and in the connected state, the fork arms of the contact element are electrically insulated from the penetrated shielding by the insulating element associated with each fork arm. The contact element is thus particularly suitable for electrically connecting conductors to shielded cables. Upon connection, the fork contact of the contact element first pierces the cable's insulation sheath and then separates the shielding.

[0011] The sharp edges of the fork arms allow the respective layer to be cut, with the insulating sections arranged laterally to the fork arms further separating the layer during a subsequent feed. In the final position, the electrical conductor is positioned between the fork arms and is automatically electrically contacted by the inner surfaces of the fork arms. The section of shielding located between the fork arms is reshaped at its sides during the insertion of the contact element into the cable in the feed direction of the contact element and then rests against the insulating elements, but not against the electrically conductive fork arms.

[0012] According to an advantageous embodiment of the invention, a sharp-edged cutting edge and / or point is formed on one or both fork arms, projecting outwards from the insulating element attached to the fork arm. In this way, the contact element can be pressed directly through the insulation sheath and, if present, the shielding without prior preparation of the cable, in particular without stripping. The cutting edge and / or point easily penetrates the insulation sheath and the shielding. In an advantageous embodiment, the cutting edge and / or point can be arranged at a free end of the respective fork arm. The cutting edge and / or point can project outwards in the longitudinal direction of the fork arms and / or in the transverse direction from the insulating element.

[0013] According to an advantageous embodiment of the invention, the fork arms, spaced apart from one another by the gap, have opposing cutting edges between which a cutting gap is formed. In this way, the insulation covering and, if present, the shielding can be reliably separated by a cutting operation.

[0014] According to an advantageous embodiment of the invention, at least one insulating element associated with each fork arm projects at least partially into the space between the fork arms and protrudes there from the fork arm. This part of the insulating element projecting into the space can be arranged, in particular, in the region of the free end of the respective fork arm. This ensures, particularly in the case of shielded cables, that all parts of the shield, including those located between the fork arms, are reliably insulated from the electrically conductive fork arms when the fork contact is connected to the cable in the manner described.

[0015] The insulating element(s) can be molded directly onto the fork contact or fork arms during manufacturing, for example, by injection molding or bonding an insulating plastic material onto them. Alternatively, the fork arms can be at least partially overmolded with an insulating plastic material. The insulating element(s) can also be designed as separate components from the fork arms.

[0016] According to an advantageous embodiment of the invention, one, several, or all of the insulating elements are attached to at least one of the fork arms by means of a positive locking mechanism. This has the advantage that the insulating elements can be manufactured as individual components and then connected to the fork contact or the fork arms by positive locking. In this way, the insulating elements can be attached to the fork contact as needed, for example, when a shielded cable needs to be connected.

[0017] Depending on the design of the insulating element(s), they can be formed as individual, separate components, with each insulating element being attached to a fork arm as a separate component. It is also possible to combine several insulating elements into a single unit, which is then attached to the fork contact or fork arms.

[0018] According to an advantageous embodiment of the invention, the contact element is designed as an insulation displacement contact, which is configured to cut through the insulation covering and / or the shielding of the cable and to clamp the at least one electrical conductor of the cable in the space between the fork arms.

[0019] The aforementioned problem is also solved by an electrical connector for stripping the insulation and connecting at least one electrical contact element of the connector to an electrical conductor of a cable with an insulating sheath, in which at least one electrical conductor is arranged within the insulating sheath, and wherein the at least one electrical contact element of the connector is designed as a contact element of the type described above. This also allows the advantages described above to be realized. Such an electrical connector is suitable for connecting to virtually any cable, in particular cables in the form of flat conductors, such as ribbon cables. For this purpose, the connector can have a plurality of contact elements of the type described above.

[0020] According to an advantageous embodiment of the invention, the connector is designed for the stripping-free connection of multiple electrical contact elements of the connector to various electrical conductors of the cable, wherein the multiple electrical contact elements of the connector are designed as contact elements of the type described above. With such a connector, cables with a multitude of electrical conductors can be connected easily and quickly, particularly without the need for separate stripping processes. The individual electrical conductors of the cable are reliably and separately contacted by a contact element without causing unwanted short circuits between the contact elements themselves or between the contact elements and parts of the cable.

[0021] The aforementioned problem is also solved by an electrical system comprising an electrical connector of the type described above and a multi-core cable with an insulating sheath, in which several electrical conductors are arranged within the insulating sheath, wherein one or more electrical conductors of the cable are electrically contacted by a respective electrical contact element of the connector without prior stripping, the respective contact element having penetrated the insulating sheath and, if present, the shielding of the cable. The advantages described above can also be realized in this way.

[0022] For the purposes of the present invention, the indefinite term "a" is not to be understood as a numeral. Therefore, when, for example, a component is mentioned, this is to be interpreted as "at least one component". Where angles are specified in degrees, these refer to a circle of 360 degrees (360°).

[0023] The invention is explained in more detail below with reference to exemplary embodiments and drawings.

[0024] They show Fig. 1 an electrical contact element in top view in exploded view, Fig. 2 the electrical contact element according to Fig. 1 in perspective view, Fig. 3 the electrical contact element according to Fig. 1 in top view, Fig. 4 the electrical contact element in the in Fig. 3. Drawing section plane BB, Fig. 5 the electrical contact element in the in Fig. 4 drawn section plane GG, Fig. 6 an isolation element in perspective view, Fig. 7 an electrical system, Fig. 8 Another embodiment of an electrical contact element in top view in exploded view, Fig. 9 the electrical contact element according to Fig. 8 in perspective view, Fig. 10 an isolation element in perspective view, Fig. 11 the electrical contact element according to Fig. 8 in top view, Fig. 12 the electrical contact element in the in Fig. 11 drawn section plane DD, Fig. 13 another embodiment of an electrical system, Fig. 14 Another embodiment of an electrical contact element in top view in exploded view, Fig. 15 the electrical contact element according to Fig. 14 in perspective view, Fig. 16 an isolation element in perspective view, Fig. 17 the electrical contact element according to Fig. 14 in top view, Fig. 18 the electrical contact element in the in Fig. 17 drawn section plane FF, Fig. 19 another embodiment of an electrical system, Fig. 20 another embodiment of an electrical contact element in top view, Fig. 21 the electrical contact element according to Fig. 20 in section view, Fig. 22 another embodiment of an electrical system, Fig. 23 another embodiment of an electrical contact element in top view, Fig. 24 the electrical contact element according to Fig. 23 in sectional view, Fig. 25 another embodiment of an electrical system, Fig. 26 another embodiment of an electrical system.

[0025] Based on the Fig. In sections 1 to 6, an embodiment of an electrical contact element 1 is described in which two insulating elements 3, designed as separate components, are used. The contact element 1 has a fork contact 2, which is made of electrically conductive material and has a main body 20. Two fork arms 21 project from the main body 20, essentially parallel to each other and spaced apart from one another. This spacing creates a gap 22 between the fork arms 21. The fork arms 21 have outwardly facing (outer) side edges 24 on their sides facing away from each other and away from the gap 22, and inwardly facing (inner) side edges 27 on their sides facing the gap 22.The inner side edges 27 serve to clamp the electrical conductor received in the space 22, so that it is securely mechanically and electrically connected to the fork arms 21 and thus to the entire fork contact 2 by means of a clamping force.

[0026] The fork arms 21 each have side surfaces 25, via which the inner side edge 27 is connected to the outer side edge 24 of the fork arm 21. In the region of their free ends, the fork arms 21 each have a sharp-edged cutting edge or point 23, which serves to cut and penetrate the insulation sheath and, if applicable, the shielding of the cable. For fastening the insulation elements 3, each fork arm 21 can have at least one first locking element 26, to which the insulation element 3 can be attached by means of a positive locking action.

[0027] As mentioned, the insulating elements 3 are designed as separate components made of an insulating material. The insulating elements 3 can have a substantially U-shaped profile with an interior 35 in which, when the insulating element 3 is attached to the respective fork arm 21, a portion of the fork arm 21 is received. A second locking element 31 can be formed on the insulating element 3, by means of which the insulating element 3 can be locked onto the associated fork arm 21.

[0028] As can be seen, each insulating element 3 encompasses the associated fork arm 21 in the area of ​​the outer side edge 24 and at least parts of the side surfaces 25. At least certain areas of the inner side edges 27 remain exposed, i.e., they are not covered by the insulating element 3, in order to ensure reliable electrical contact of the electrical conductor. For this purpose, the insulating elements 3 can have a clearance area 30 in which they do not cover the respective inner side edge 27 and parts of the side surface 25. Additionally, the insulating elements 3 can have a recess 32 in the area where they cover at least the free end of the fork arm 21 on the side surfaces 25.The recess 32 ensures that the sharp-edged cutting edge or tip 23 is sufficiently exposed, so that the separation functionality of the insulation covering and, if applicable, the shielding required for the stripping-free connection of the contact element 1 is ensured.

[0029] In the embodiment according to the Fig. 1 to 6 the insulation elements 3 are arranged to move laterally towards the respective outer side edge 24, as indicated by the arrows in the Fig. 1 and Fig. 2 indicated, to be mounted on the respective fork arm 21. The respective insulating element 3 engages with a material section in the first locking element 26 and also engages behind the associated fork arm 21 with its second locking element 31, as shown in the Fig. Figures 3 to 5 illustrate this. In this way, the insulating element 3 is securely held to the associated fork arm 21 by positive locking in all spatial directions.

[0030] The Fig. Figure 7 shows an electrical system in which an electrical connector 5 is connected to a multi-core cable 4 by means of a wire-free connection. The cable 4 is shown in cross-section. The electrical connector 5 has one or more electrical contact elements 1, e.g., electrical contact elements 1 of the type described above, which are held, for example, in a housing of the connector 5.

[0031] The cable 4 has an outer insulating sheath 41 (sheath insulation) inside which a shield 42 is arranged. An inner insulating sheath 43 is located within the shield 42. Several electrical conductors 40 are arranged side by side within the inner insulating sheath 43. The electrical conductors 40 are insulated from each other by the inner insulating sheath 43.

[0032] As can be seen, the electrical contact element 1 has penetrated the outer insulation covering 41, the shielding 42 and the inner insulation covering 43, whereby an electrical conductor 40 is received in the space 22 between the fork arms 21 and is electrically contacted there at the inner side edges 27.

[0033] Based on the Fig. Sections 8 to 12 describe an embodiment of an electrical contact element 1 which, like the previously described electrical contact element 1, has a fork contact 2 and two insulating elements 3 designed as separate components. The fork contact 2 can be designed as described previously. The insulating elements 3 are designed at least similarly to the insulating elements 3 of the previously described embodiment, wherein in the embodiment of Fig. 8 to 12 the insulation elements 3 are arranged to be placed on the fork arms 21 in a longitudinal direction, i.e. essentially parallel to the longitudinal extension direction, as indicated by the arrows in the Fig. 8 and Fig. Figure 9 illustrates this. For this purpose, the insulating element 3 has two second locking elements 33, 34, which are spaced apart from each other and are designed to bear against the inner side edge 27 of the fork arm 21 and fix the insulating element 3 there. The additional locking of the insulating element 3 on the first locking element 26 of the fork arm 21 ensures, as in the first described embodiment, a secure positive locking of the insulating element 3 in all spatial directions on the fork arm 21.

[0034] The Fig. Figure 13 shows an electrical system similar to the Fig. 7, where a connector 5 with a contact element 1 is used, which according to the Fig. is trained from ages 8 to 12.

[0035] Based on the Fig. Figures 14 to 18 describe an embodiment of an electrical contact element 1, which in turn has a fork contact 2 of the type described above. In this case, an insulating element 3 is used, which is designed as a one-piece unit and is configured for attachment to both fork arms 21. The insulating element 3 is slipped over the fork contact 2 or the fork arms 21 like a sleeve, with the fork arms 21 being received in the interior 35 of the insulating element 3. The insulating element 3 can in turn be snapped onto the first locking elements 26.

[0036] Since the insulating element 3 extends, at least in its upper region, in a transverse direction from one fork arm 21 to the second fork arm 21, an elongated clearance 36 is additionally formed in the insulating element 3. When the insulating element 3 is mounted on the fork contact 2, this clearance overlaps with the space 22, thus providing the necessary clearance for receiving the electrical conductor 40. Furthermore, the insulating element 3 can be shaped similarly to the previously described insulating elements, in particular with the clearance area 30 and the recess 32.

[0037] The Fig. Figure 19 shows an electrical system similar to Fig. 7, wherein the connector in this case is equipped with at least one electrical contact element 1 according to the Fig. trained from ages 14 to 18.

[0038] Based on the Fig. 20 and Fig. 21 describes a further embodiment of an electrical contact element 1, which corresponds to the embodiment of the Fig. 8 to 12 largely corresponds to it and differs from it only in the following respect. While in the embodiment of the Fig. 8 to 12 the insulating elements 3 are largely open towards the space 22 and are only closed there by a narrow bridge, which forms the second locking element 33, is shown on the basis of the Fig. 20 and Fig. 21 proposes an embodiment of the contact element 1 in which the insulating elements 3 are closed by insulating material towards the gap 22, at least in the areas furthest from the free ends of the fork arms 21, so that a second locking element 33 is formed in the longitudinal direction of the fork arms 21 in the form of a relatively long closed section. This means that the fork arms 21 are covered with insulating material of the insulating elements 3 in this area towards the gap 22. As a result, the fork arms 21 are largely or completely enclosed by insulating material in their upper region. This further improves the desired insulating effect of the insulating elements 4 against the shielding 42 or other electrically conductive elements.

[0039] The Fig. Figure 22 shows an electrical system similar to the Fig. 13, wherein a contact element 1 according to the Fig. 21, Fig. 22 is inserted and connected to cable 4.

[0040] The Fig. 23 and Fig. Figure 24 shows an embodiment of a contact element 1 with an insulating element 3, which, apart from the differences explained below, is identical to the embodiment described above. Fig. 14 to 18 corresponds. A one-piece insulating element 3 is again used, which is attached to the contact element 1. Similar to the embodiment described above. Fig. 20 and Fig. As explained in Figure 21, the insulating element 3 is also designed here with additional internal insulating sections that point towards the space 22, so that the elongated free space 36 is narrower than in the embodiment of the Fig. 14 to 18. As can be seen, in the embodiment of the Fig. 23, Fig. 24 The space 22 in the upper area is largely filled with the insulating material of the insulating element 3, so that the insulating material also covers the inner side edges 27 of the fork arms 21 in the upper area. This also further increases the shielding effect of the insulating element.

[0041] The Fig. Figure 25 shows an electrical system similar to the Fig. 19, wherein a contact element 1 according to the Fig. 23 and Fig. 24 is used and is connected to cable 4.

[0042] The electrical contact element 1 according to the invention is also advantageously suitable in all embodiments for stripping-free connection to a cable 4 where the shielding 42 is not present. This is illustrated by way of example by the Fig. 26 illustrates this. A contact element 1 is shown as an example, according to the Fig. 20 and Fig. 21 is used, but as mentioned, any other embodiment can also be used.

[0043] As the Fig. As further illustrated in Figure 26, the electrical contact element 1, due to its construction with the insulating element 3 or insulating elements 3, is also well suited for contacting cables 4 where the internal electrical conductors 40 are arranged relatively close together and / or the positioning of the contact element on the cable 4 during the connection process, i.e., when inserting the contact element through the insulating covering, is imprecise. Even then, the reliability of the correct electrical contact of an electrical conductor 40 arranged in the insulating covering 41, 43 is ensured to the best possible extent. Reference symbol list 1 electrical contact element 2 Fork contact 3 Insulation element 4 cables 5 electrical connectors 20 main bodies 21 Fork arm 22 space 23 sharp-edged cutting edge or point 24 outer side edge 25 side surface 26 first locking element 27 inner side edge 30 Clearance area 31 second locking element 32 recess 33 second locking element 34 second locking element 35 Interior 36 elongated free space 40 electrical conductors 41 outer insulation covering 42 Shielding 43 inner insulation covering

Claims

[1] Electrical contact element (1) for stripping-free connection to a cable (4) formed with an insulating covering (41, 43), in which at least one electrical conductor (40) is arranged inside the insulating covering (41, 43), having the following features: a) the contact element (1) has an electrically conductive fork contact (2) with two fork arms (21) spaced apart from each other by a gap (22), b) the contact element (1) is designed to receive and electrically contact the electrical conductor (40) in the space (22) between the fork arms (21), c) the contact element (1) has an insulating element (3) on each of the two fork arms (21), by which the fork arms (21) are electrically insulated at least on the sides (24) facing away from each other. [2] Contact element according to claim 1, characterized by, that in each of the fork arms (21) the side (27) facing the space (22) is connected via at least one side surface (25) to the side (24) facing away from the space (22), wherein at least one insulating element (3) assigned to the respective fork arm (21) also covers at least partially electrically insulating one side surface (25) or two opposing side surfaces (25) of the fork arm (21). [3] Contact element according to one of the preceding claims, characterized by , that the contact element (1) is configured to penetrate a shield (42) of the cable (4), wherein in the state of the contact element (1) being connected to the cable (4) the fork arms (21) are electrically insulated from the penetrated shield (42) by the insulating element (3) associated with the respective fork arm (21). [4] Contact element according to any one of the preceding claims, characterized by, that a sharp-edged cutting edge and / or point (23) is formed on one or both fork arms (21) which protrudes towards the insulating element (3) attached to the fork arm (21). [5] Contact element according to any one of the preceding claims, characterized by , that the fork arms (21) spaced apart from each other by the gap (22) have opposing cutting edges between which a cutting gap is formed. [6] Contact element according to any one of the preceding claims, characterized by , that at least one insulating element (3) assigned to the respective fork arm (21) projects at least partially into the space (22) between the fork arms (21) and protrudes there opposite the fork arm (21). [7] Contact element according to any one of the preceding claims, characterized by that one, several or all of the insulating elements (3) are attached to at least one of the fork arms (21) by means of a positive locking mechanism. [8] Contact element according to any one of the preceding claims, characterized by , that the contact element (1) is designed as an insulation displacement contact, which is designed to cut through the insulation covering (41, 43) and / or the shielding (42) of the cable (4) and to clamp the at least one electrical conductor (40) of the cable (4) in the space (22) between the fork arms (21). [9] Electrical connector (5) for stripping at least one electrical contact element (1) of the connector (5) to an electrical conductor (40) of a cable (4) formed with an insulating covering (41, 43), in which at least one electrical conductor (40) is arranged inside the insulating covering (41, 43), characterized by , that the at least one electrical contact element (1) of the connector (5) is designed as a contact element (1) according to one of the preceding claims. [10] Electrical connector according to claim 9, characterized by , that the connector (5) is designed for the stripping-free connection of several electrical contact elements (1) of the connector (5) to different electrical conductors (40) of the cable (4), wherein the several electrical contact elements (1) of the connector (5) are designed as contact elements (1) according to one of claims 1 to 8. [11] Electrical system comprising an electrical connector (5) according to claim 9 or 10 and a multi-pole cable (4) formed with an insulating covering (41, 43) in which several electrical conductors (40) are arranged within the insulating covering (41, 43), wherein one or more electrical conductors (40) of the cable (4) are electrically contacted by a respective electrical contact element (1) of the connector (5) without prior stripping, wherein the respective contact element (1) has penetrated the insulating covering (41, 43) and, if present, the shielding (42) of the cable (4).

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