Electrical contact element, connector and use

Abstract

Electrical contact element (1) with a hollow cylindrical region (2), wherein the hollow cylindrical region (2) has on its inner side a radially circumferential mounting groove (5) for receiving and securing a contact strip (10), which is designed as a trapezoidal groove with a free space tapering towards the inside, and on its outer side a substantially axially extending slot (4) for inserting the contact strip (10), wherein the slot (4) is arranged opposite the mounting groove (5) and extends from the outside into the mounting groove (5), wherein a length of the slot (4) corresponds to at least a width of the mounting groove (5) at its base, and wherein the contact strip (10) can be inserted radially through the slot (4) into the mounting groove (5).

Description

Technical field

[0001] The invention relates to an electrical contact element, a connector and its use. State of the art

[0002] WO 2008 / 122895 describes a two-part electrical connection in which a self-reinforcing contact strip connects two contact parts. The contact strip is held in a groove in one of the contact parts by self-reinforcing projections that engage in slots in the bottom of the groove. However, using contact strips on the inside of cylindrical round contacts presents significant disadvantages. Manufacturing grooves and slots with the required tolerances can be more difficult on the interior of hollow cylindrical round contacts. Furthermore, inserting and removing the contact strip can be difficult due to limited access. These stresses can compromise the retention of the contact strip in the groove and potentially lead to contact failure.

[0003] DE 102011101341 A1 discloses stamped electrical contact arrangements with spiral springs in rolled housings. The spring is held in a groove formed by bending. However, this design is primarily intended for flat, stamped arrangements and has disadvantages with regard to spring retention and assembly when used with hollow cylindrical round contacts.

[0004] German patent DE 102004002404 B3 describes spring elements with arc-shaped contact tongues that are inserted into the housing through a tangential opening. However, this tangential assembly requires special tools, weakens the housing integrity, and significantly complicates repairs. Task

[0005] The present invention is based on the objective of providing an electrical contact element, a connector and a use which overcome the disadvantages and limitations of the prior art.

[0006] The present invention further aims to provide an electrical contact element, a connector and a use that enables the use of a self-springing contact band inside a hollow cylindrical area of ​​an electrical contact element, wherein the self-springing contact band is easily insertable and removable from the interior of the area and is held securely there, which can lead to an exceptionally high reliability of the contact quality with a mating contact element and enables cost-effective manufacturing.

[0007] According to the invention, these problems are solved by an electrical contact element, a connector and a use according to the independent claims.

[0008] Further advantageous embodiments are specified in the dependent claims.

[0009] In a first aspect of the invention, an electrical contact element with a hollow cylindrical region is disclosed. The hollow cylindrical region has on its inner side a radially circumferential mounting groove for receiving and securing a contact strip, which is designed as a trapezoidal groove with a clearance that tapers towards the inside, and on its outer side a substantially axially extending slot for inserting the contact strip, wherein the slot is arranged opposite the mounting groove and extends from the outside into the mounting groove, wherein the length of the slot corresponds to at least one width of the mounting groove at its base, and wherein the contact strip can be inserted radially through the slot into the mounting groove.

[0010] In this context, radial and axial refer to an axis of rotation that runs centrally through the hollow cylindrical shape. Preferably, the hollow cylindrical shape is a circular hollow cylinder, as is found in hollow cylindrical round contacts in connectors.

[0011] Furthermore, the length of the slot refers to the axial extent of the slot and the width of the fastening groove to the radial extent of the fastening groove, each with reference to the aforementioned axis of rotation.

[0012] The essentially axially extending slot runs approximately parallel to the axis of rotation and preferably has a deviation of less than 20°, in particular less than 10°, preferably less than 5° and most preferably less than 2.5° from the axis of rotation.

[0013] The electrical contact element is specifically designed for use in high-current applications.

[0014] The electrical contact element can also be designed as a hollow cylindrical round contact, instead of only having a hollow cylindrical area.

[0015] The contact strip can advantageously be inserted into or removed from the mounting groove from the outside through the slot, which on the one hand facilitates assembly and disassembly and on the other hand leads to reliable contact between the contact strip and the contact body of the electrical contact element.

[0016] The hollow cylindrical area can have a cylindrical wall and the slot can completely penetrate the cylindrical wall, with the slot having a radially extending chamfer, i.e., a narrow surface adjoining the slot.

[0017] The hollow cylindrical area can have an opening for inserting a counter-contact element, wherein the slot and the fastening groove can be arranged on a side facing the opening and wherein the slot and the fastening groove can preferably be spaced apart from an edge of the opening.

[0018] The fastening groove is designed as a trapezoidal groove with a clearance that tapers towards the inside of the hollow cylindrical section. This can mean that the widest point of the groove lies within the wall of the hollow cylindrical section.

[0019] The trapezoidal groove offers the advantage that, when a force is applied to the self-resilient contact strip, such as during insertion, the contact strip is securely held in the groove. The flanks of the trapezoidal groove can grip the self-resilient contact strip at its edge.

[0020] The length of the slot corresponds at least to the width of the fastening groove at the base, i.e., at the bottom of the trapezoidal groove.

[0021] The electrical contact element can have a radially circumferential contact band arranged in the mounting groove, which can become part of the electrical contact element after assembly.

[0022] The contact strip can be designed as a self-springing contact strip with a plurality of current bridges, wherein the current bridges can be connected to an edge support strip via torsion joints and wherein the edge support strip can be in mechanical engagement with the fastening groove.

[0023] The material of the hollow cylindrical section, i.e., the contact body, can differ from the material of the contact strip. The contact body can preferably be made of copper, brass, or bronze, which are typically used for high-current contacts in connectors. The contact strip, on the other hand, can be made of a copper-beryllium alloy.

[0024] Even if the training courses relate to individual aspects, they can be combined in any way possible, provided this is technically feasible and makes sense.

[0025] In a second aspect of the invention, a connector is disclosed which comprises an electrical contact element according to the first aspect (including all further developments or combinations thereof), in particular an electrical contact element with a self-springing contact strip received in the mounting groove, and a housing that at least partially receives the electrical contact element. The connector has the aforementioned advantages of the electrical contact element.

[0026] A third aspect of the invention discloses the use of a connector according to the second aspect for high-current applications. The connector is specifically designed for currents exceeding 50 A, preferably exceeding 200 A, and most preferably exceeding 400 A.

[0027] Its use in high-current applications optimally utilizes the advantages of the electrical contact element, in particular the reliable contacting through the self-springing contact strip and the easy assembly through radial access via the slot. Example of implementation

[0028] An embodiment of the invention is shown in the drawings and is explained in more detail below. The drawings show: Fig. 1 a perspective view of an electrical contact element; Fig. 2 an electrical contact element with a self-springing contact band and a mating contact; Fig. 3A, Fig. 3B a sectional drawing of the electrical contact element with mounting groove; Fig. 4A, Fig. 4B a self-sprung contact strip from different perspectives.

[0029] The figures contain simplified, schematic representations. In some cases, identical reference symbols are used for elements that are the same but may not be identical. Different views of the same elements may be scaled differently. Directional indications such as "left," "right," "up," and "down" are to be understood in relation to the respective figure and may vary from one representation to the actual object depicted.

[0030] Fig. Figure 1 shows an electrical contact element 1 that can be used in a connector for contacting and is designed for high-current applications, i.e., for a current of more than 50 A, preferably more than 200 A, and particularly preferably more than 400 A. This means that such high currents can be carried under normal operating conditions of the connector.

[0031] The electrical contact element comprises a contact body with a hollow cylindrical region 2 and an adjoining contacting region 3, which can be configured for contact with a conductor of a cable or busbar. The contact body is preferably made of a highly conductive material, such as a copper alloy commonly used for electrical contacts.

[0032] On the outside of the electrical contact element 1, a through-opening is visible, extending into the interior of the hollow cylindrical area 2 and forming an elongated slot 4. The slot 4 runs essentially parallel to an axis of rotation (not shown), but can also run at a certain angle, e.g., 45°, to the axis of rotation.

[0033] Furthermore, the hollow cylindrical section 2 of the electrical contact element 1 has an almost completely radially circumferential mounting groove 5 inside, which can receive and detachably secure a self-springing contact strip. The mounting groove 5 is accessible through the slot 4, so that the slot 4 extends through the mounting groove 5 into the interior of the hollow cylindrical section 2. The slot 4 has a chamfer 4' in a radial direction onto which a contact strip can be placed. As can also be seen, the slot 4, the chamfer 4', and the mounting groove 5 are arranged spaced apart from the edge of the opening on the right side.

[0034] Fig. Figure 2 shows the electrical contact element 1. Fig. 1 with a mating contact element 1', which can be designed as a fully cylindrical component and can be inserted into the electrical contact element 1 from the right in the direction of the arrow. The diameter of the mating contact element 1' is smaller than the diameter of the hollow cylindrical section of the electrical contact element 1. The figure also shows a self-resilient contact band 10, which rests against the chamfer of the electrical contact element 1. By inserting it M in a radial direction, as indicated by the arrow, the self-resilient contact band 10 can be inserted through the slot 4 into the mounting groove.

[0035] Preferably, the self-resilient contact strip 10 is pre-cut to the required length, which corresponds approximately to the inner circumference of the hollow cylindrical area, before being inserted into the mounting groove. The self-resilient contact strip 10 then forms an almost completely radial contact surface inside. Alternatively, a long contact strip 10 can be pushed through the slot 4 until a semi-circular or completely circumferential contact surface is formed, and the contact strip 10 is then cut to the appropriate length in a second step.

[0036] Fig. Figure 3A shows a section through the electrical contact element 1 with the contact body, which has the hollow cylindrical section 2 and a fastening groove 5 formed in the cylindrical wall 2' of the contact body. The fastening groove 5 is, as previously described, almost completely radially circumferential and designed to receive and fasten the self-springing contact strip.

[0037] As can be seen further (in the circled area), the length of the slot (i.e. the axial extent) corresponds approximately to the width of the fastening groove 5, particularly in a base or bottom section of the fastening groove 5.

[0038] In Fig. Figure 3B shows the mounting groove 5 of the electrical contact element 1 in the circled area. As can be seen, the mounting groove 5 is a trapezoidal groove, also known as a dovetail groove, with flanks that taper towards the interior of the hollow cylindrical area at an angle α of approximately 45°. The base or bottom section of the trapezoidal groove (i.e., the area with the greatest width) lies within the cylindrical wall of the contact body and has a width W in its base section that is at least equal to the slot length. This ensures that the self-springing contact strip can be inserted through the slot into the mounting groove. Furthermore, the width of the slot should be at least equal to the height of the self-springing contact strip.

[0039] The trapezoidal groove can be produced using a suitable tool, such as a chisel or die, on a lathe. The slot can be produced with a milling cutter, preferably after the trapezoidal groove has been machined.

[0040] Fig. Figure 4A shows a side view of the self-reinforcing contact strip 10. The self-reinforcing contact strip 10 has a total height h, which is composed of the height of the lower contact sections B and the height of the upper contact sections A. The two contact sections A and B together form a current bridge, and the self-reinforcing contact strip 10 has a plurality of current bridges. When the self-reinforcing contact strip 10 is inserted into the mounting groove, the lower contact sections B rest against the cylindrical wall of the contact body or against the bottom section of the trapezoidal groove. The upper contact section A, on the other hand, would form an electrically conductive connection with the mating contact element. The lower and upper contact sections A and B are spaced apart by a distance D. As already indicated, the gap width corresponds at least to the total height h of the self-reinforcing contact strip 10.

[0041] As from Fig.As can be seen in Figure 4B, the individual contacts, consisting of the lower and upper contact sections A and B, are connected to the edge support strip S via torsion joints C. When the contact spring strip 10 is inserted into the mounting groove, the edge support strip S engages with the flanks of the mounting groove, so that the flanks of the mounting groove hold the contact spring strip 10, through which a portion of the electrical current is also transferred from the mating contact element to the electrical contact element. The width of the bottom area of ​​the mounting groove corresponds at least to the width w of the contact strip 10.

[0042] The design of the electrical contact element's contact body allows the self-springing contact strip to be inserted into and removed from the mounting groove through the slot from the outside, without requiring significant effort in the manufacturing process (i.e., final assembly) of the electrical contact element or any connector housing it. This enables cost-effective production and easy repair of the electrical contact element. Furthermore, no special tools are required for manufacturing (final assembly). Inserting the contact strip through the slot also ensures a secure hold in the groove.

[0043] Even though the figures show various aspects or features of the invention in combination, it is apparent to the person skilled in the art – unless otherwise stated – that the combinations shown and discussed are not the only possible ones. In particular, corresponding units or sets of features from different embodiments can be interchanged. Reference symbol list 1 Electrical contact element 1' Counter contact element 2 Hollow cylindrically shaped areas 2' Cylinder wall, wall of the contact body 3 Contact area 4 slots 4' phase 5 Mounting groove (trapezoidal groove) 10 self-springing contact strips A Upper contact section B Lower contact section C Torsion joint D Distance between the contact sections, or current bridges h Total height of a power bridge M movement, insertion or plugging R axis of rotation or turning S edge area or edge strip of the contact tape W width of the contact strip or width at the bottom of the mounting groove α Tapering angle of the mounting groove 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] WO 2008 / 122895

[0002] DE 102011101341 A1

[0003] DE 102004002404 B3

[0004]

Claims

[1] Electrical contact element (1) with a hollow cylindrical region (2), wherein the hollow cylindrical region (2) has on its inner side a radially circumferential mounting groove (5) for receiving and securing a contact strip (10), which is designed as a trapezoidal groove with a free space tapering towards the inside, and on its outer side a substantially axially extending slot (4) for inserting the contact strip (10), wherein the slot (4) is arranged opposite the mounting groove (5) and extends from the outside into the mounting groove (5), wherein a length of the slot (4) corresponds to at least a width of the mounting groove (5) at the base, and wherein the contact strip (10) can be inserted radially through the slot (4) into the mounting groove (5). [2] Electrical contact element (1) according to claim 1, wherein the hollow cylindrical area (2) has a cylinder wall (2') and wherein the slot (4) completely penetrates the cylinder wall (2') and wherein the slot (4) preferably has a chamfer (4') extending in a radial direction. [3] Electrical contact element (1) according to claim 1 or 2, wherein the hollow cylindrical area (2) has an opening for inserting a mating contact element (1'), wherein the slot (4) and the fastening groove (5) are arranged on a side facing the opening, and wherein the slot (4) and the fastening groove (5) are preferably arranged spaced apart from an edge of the opening. [4] Electrical contact element (1) according to one of claims 1 to 3, comprising a radially circumferential contact band (10) arranged in the mounting groove (5). [5] Electrical contact element (1) according to claim 4, wherein the contact band (10) is designed as a self-springing contact band with a plurality of current bridges (A, B), wherein the current bridges (A, B) are connected to an edge support strip (S) via torsion joints (C) and wherein the edge support strip (S) is in mechanical engagement with the fastening groove (5). [6] Electrical contact element (1) according to claim 4 or 5, wherein the material of the hollow cylindrical area (2) differs from the material of the contact strip (10). [7] Connector comprising an electrical contact element (1) according to one of claims 4 to 6 and a housing designed to receive the electrical contact element. [8] Use of a connector according to claim 7 for currents of more than 50 A.

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