Contact arrangement for high current applications

Abstract

Plug contact (10) with at least one plug extension (12), in particular at least one contact pin and with at least one plug receptacle (11) into which the plug extension (12) can be inserted in the plug-in direction, wherein the plug receptacle (11) is formed by - a first, ring-shaped contact frame (13) which encloses a plug channel (14) for receiving the plug extension (12), - at least one connecting part (16), such as a solder joint or conductor connection on the first contact frame (13), by means of which the plug contact (10) is to be connected to an electrically conductive component, such as a circuit board, stamped grid or connecting conductor, - at least two contact fingers (15) which emerge from the contact frame (13) in the same direction and spring-return elastically into the plug channel (14) to electrically contact the plug extension (12), wherein - each contact finger (15) forms a contact area with which it makes contact with the plug-in extension (12) when the plug-in extension (12) is inserted, and whereby - the plug socket (11) is designed without a support cage, - the contact fingers (15) are only attached to the first contact frame (13) and - the contact forces of the contact fingers (15) are realized exclusively through their inherent elasticity in conjunction with their connection to the contact frame (13), characterized by the fact that - a second, ring-shaped contact frame (18) is assigned to the first contact frame (13), - the second contact frame (18) is arranged on the first contact frame (13) via at least one bridge (19, 20) oriented parallel to the insertion direction of the insertion extension (12), - the first (13) and second contact frames (18) take the contact fingers (15) between them - the contact fingers (15) are arranged without contact to the second contact frame (18).

Description

[0001] The invention relates to a plug connector with at least one plug-in extension, in particular at least one contact pin, and with at least one plug receptacle into which the plug-in extension can be inserted in the plug-in direction, wherein the plug receptacle is formed by a first, ring-shaped contact frame which encloses a plug-in channel for receiving the plug-in extension, at least one connecting element, such as a solder joint or conductor connection on the first contact frame, by means of which the plug connector is to be connected to an electrically conducting component, such as a circuit board, stamped grid or connecting conductor, and at least two contact fingers which extend from the contact frame in the same direction and are spring-returned into the plug-in channel in order to electrically contact the plug-in extension, wherein each contact finger forms a contact area with which it bears contact against the plug-in extension when the plug-in extension is inserted. and wherein the plug receptacle is designed without a support cage, the contact fingers are only connected to the first contact frame and the contact forces of the contact fingers are realized exclusively through their inherent elasticity in conjunction with their connection to the first contact frame.

[0002] The invention relates to contacts for high-current applications, that is, for applications in which current strengths of at least 50 amperes, in particular 70 or more amperes and preferably powers of over 90 amperes are transferred via the contacts.

[0003] In the prior art, which is not documented in print, so-called "lamellar contacts" have proven effective for this purpose. These are plug-in contacts, usually circular or rectangular in shape. A multitude of contact arms protrude into a plug channel. A mating contact, in particular a contact pin, is inserted into this plug channel. This mating contact is contacted by all contact arms. To transmit high currents, the contact arms—the so-called contact lamellae—must have sufficient contact pressure to keep the electrical contact resistance as low as possible. This is often achieved by mounting the contact frame with the contact lamellae within a support cage, usually a sleeve surrounding the plug-in contact. The contact lamellae can thus bear against the support frame.If the counter-contact is used, higher pressure forces can be achieved by supporting the lamellae on the support cage.

[0004] The support cage also serves to guide the mating contact during the plugging process and to prevent damage, such as contact deformation, to the contact lamellae or contact arms through clean guidance.

[0005] Plug connectors that utilize support cages offer significant advantages with regard to the contact forces required in high-current applications and with regard to guiding the mating contact during automated plugging processes. However, combining a lamellar contact with a support cage presents disadvantages such as increased assembly effort, a larger installation space requirement due to the support cage, and a higher price.

[0006] Laminated contacts that do not require a support cage must be precisely aligned, especially with regard to the exact positioning of the mating contact during insertion processes, i.e., with regard to radial misalignment or angular tilt. Even slight tilts and misalignments of the mating contact to the plug contact can lead to contact damage or insufficient contact quality.

[0007] Both contact types, that is, contacts with and without a support cage, share another disadvantage. This lies in the lack of precisely defined contact zones. This prevents exact contact positioning of the lamellae on the mating contact, which is detrimental to the electrical transition from the mating contact to the plug contact.

[0008] The invention is based on a support cage-less plug connector. The object of the invention is to make this connector more variable with regard to positional tolerances of the mating contact.

[0009] The problem is solved by a plug connector with the features of claim 1, in particular with its characterizing features, according to which - a second, ring-shaped contact frame is assigned to the first contact frame, - the second contact frame is arranged on the first contact frame via at least one bridge oriented parallel to the insertion direction of the plug-in extension, - the first and second contact frames take the contact fingers between them - the contact fingers are arranged without contact to the second contact frame.

[0010] The primary insertion direction of the plug connector according to the invention is directed towards the free ends of the contact fingers in the direction of the first contact frame. The contact fingers narrow the plug channel by spring-returning into it, so that the mating contact, upon insertion into the plug channel, displaces the contact fingers radially outwards from their rest position. Due to the spring-return elasticity, this displacement creates a contact point between the contact fingers and the mating contact, which in this specific embodiment is designed as a contact pin.

[0011] The second contact frame, located at the front in the primary insertion direction, is passed first when the mating contact, especially the contact pin, is inserted. The mating contact then moves further into the area of ​​the contact fingers and, as it is inserted, moves towards the first contact frame.

[0012] The second contact frame is positioned upstream of the contact fingers or contact lamellae in the primary insertion direction and serves as a protective and guiding component. A mating contact that is misaligned or tilted can be slightly corrected in its position as it passes through the second contact frame. If the mating contact is outside the tolerance range, the second contact frame ensures that the misalignment is diverted outwards, thus preventing deliberate mis-insertion or stopping the insertion process upon contact with the second contact frame. This can mean that the contact pin or mating contact slides radially outwards along the second contact frame, and therefore also radially outwards, i.e., outside the contact lamellae. In this way, it is prevented that a mating contact with an out-of-tolerance position comes into contact with the contact lamellae and damages them.Alternatively, when the mating contact strikes the second contact frame, it creates resistance that aborts the automated mating process. The user can then receive visual feedback indicating an incorrect mating.

[0013] In this way, the tolerance range is increased, especially in the case of lateral offset, but also in the case of inclination, since a correction can be made by the second contact frame, or contact reliability is increased, since an impact of the opposing contact that could damage the contact lamellae is reliably avoided.

[0014] As explained below, there can be a secondary insertion direction that is opposite to the primary insertion direction and first passes through the first contact frame to reach the contact zone of the contact fingers. In this case, the first contact frame takes over the function that the second contact frame fulfills when using the primary insertion direction.

[0015] The invention further provides that the contact area of ​​the contact fingers forms a contact tip, in that each contact finger is curved transversely to the insertion direction of the insertion process and in that each contact finger has two inclined surfaces sloping outwards away from the insertion channel, which originate from a common vertex line, wherein the contact tip is formed in the area of ​​each contact finger in which the line of curvature and the vertex line intersect.

[0016] This design creates defined and essentially point- or disc-shaped contact tips, which are particularly advantageous when the opposing contact is inclined at an angle deviating from the ideal position, but also when it is laterally offset from the ideal position. For example, the offset and inclination of the opposing contact do not result in rotation of the contact fingers about their own longitudinal axis, since no rotational forces can be introduced when the contact fingers are formed with a contact tip at an essentially point-like position along the longitudinal center axis of the invention.

[0017] By forming defined contact tips in the contact area of ​​the contact fingers, it is also ensured that the contact fingers are not forced into geometric positions in space that are detrimental to electrical contacting if the mating contact is offset or inclined.

[0018] To guarantee a uniform and defined contact zone, it is intended that the first and / or the second contact frame act as a leading element on the plug-in extension.

[0019] As mentioned above, it is intended that the first and / or the second contact frame will have a leading effect on the plug extension.

[0020] Furthermore, it is provided that the contact fingers, which are only arranged on the first contact frame, point with their free ends towards the second contact frame.

[0021] During the manufacturing of the plug connector, it is ensured that the contact fingers, which are only located on the first contact frame, point with their free ends towards the second contact frame. This ensures that the mating-oriented surface of the first and second contact frames is kept narrow. If a mating contact in the primary mating direction encounters the stamped side, i.e., the narrow edge of the first contact frame, the contact pin is prevented from sliding either in a corrective direction towards the contact fingers or, conversely, from making a false contact outside the plug receptacle.

[0022] There is an embodiment of the plug connector according to the invention in which a secondary insertion direction is opposite to the primary insertion direction. The secondary insertion direction thus first receives the mating contact via the first contact frame, whereupon the mating contact is then inserted towards the free ends of the contact fingers or towards the second contact frame in order to enter the contact area.

[0023] It is intended that the plug receptacle is designed as a sleeve-like stamped / bent part made from a sheet metal piece, with the butt edges of the sleeve-like shaped sheet metal lying in the area of ​​the web connecting the two contact frames.

[0024] It is intended that the end edges divide the bridge parallel to the insertion direction, in particular divide it in half.

[0025] A particularly preferred embodiment is one in which the end edges divide the bridge parallel to the insertion direction, in particular dividing it in half.

[0026] Further advantages of the invention and a better understanding will become apparent from the following description of an exemplary embodiment. It shows: Fig. 1: A plug connector according to the invention in a first side view, Fig. 2: A side view of the plug socket of the plug contact according to Fig. 1 directed towards a bridge connecting the first and second contact frames, Fig. 3: the plug socket of the plug contact according to Fig. 1 in perspective view, Fig. 4: A sectional view of the plug socket of the plug contact according to section line AA in Fig. 2, Fig. 5: A view of the plug socket of the plug contact according to Fig. 1 from the bottom, Fig. 6: a view of the plug socket of the plug contact according to Fig. 1 from the top, Fig. 7: A detailed view of a contact finger of the plug socket Fig. 1, Fig. 8: the plug contact after Fig. 1 with laterally offset extension, Fig. 9: the plug contact after Fig. 1 with inclined stub extension, Fig. 10: another sectional view of the plug socket of the plug contact.

[0027] In the figures, a plug contact according to the invention is provided with the reference numeral 10. Fig. Figure 1 shows the plug connector with its two essential parts, namely the plug receptacle 11 and the plug extension 12. To establish an electrical connection, the plug extension 12 is inserted into the plug receptacle 11 in the insertion direction X, primary insertion direction, or insertion direction Y, secondary insertion direction.

[0028] The plug receptacle forms the essential part of the invention. The plug receptacle comprises a first contact frame 13, which is ring-shaped, and an inner plug channel 14 enclosed by the ring. The plug channel 14 serves to guide and receive the plug extension 12 in the plug receptacle 11. A plurality of contact fingers 15 extend from the upper surface of the first contact frame 13. These extend in the opposite direction to the primary plugging direction X and are radially flared inwards, narrowing the plug channel 14. At least one connecting element 16 is located on the underside of the first contact frame 13, which preferably extends from the first contact frame 13 and is thus materially bonded to it. This connecting element 16 is designed to connect the plug receptacle 11 to an electrically conductive component. For example, the connecting element can be designed as a crimp terminal for connecting conductors.However, in the drawings, solder pins 17 are provided as connecting part 16 to fix the plug receptacle 11, for example, on a circuit board or a stamped grid and to make electrical contact there.

[0029] According to the invention, the plug receptacle 11 carries a second contact frame 18. The second contact frame 18 is fixed to the first contact frame 13 by at least one ridge 19; in the exemplary embodiment, two ridges 19 and 20 were advantageously selected. Each ridge 19, 20 extends from the first contact frame 13 opposite to the primary plugging direction X and thus essentially in the same direction as the contact fingers 15. As the figures show, the contact fingers 15 are arranged between the first contact frame 13 and the second contact frame 18. The contact fingers 15 are only in contact with the first contact frame 13. The contact fingers 15 are designed without contact with the second contact frame 18. The second contact frame 18 is also essentially ring-shaped and surrounds the plug channel 14 for the plug extension 12.

[0030] The socket is designed as a stamped / bent part. The stamped part, formed from a strip of sheet metal, is subsequently formed into its shape shown in the figures. During this process, the sheet metal strip is shaped, among other things, into a sleeve-like component. The butt edges parallel to the insertion direction are, as Fig. Figure 2 shows the arrangement in the area of ​​the bridge 19 connecting the two contact frames 13 and 18. In particular, the bridge 19 is divided in half by the end edges. In this way, the plug receptacle 11 achieves high stability.

[0031] Fig. Figure 3 shows the plug receptacle 11 in a perspective view, so that the sleeve-like shape of the plug receptacle 11 is visible, as is the ring shape of the first contact frame 13 and the second contact frame 18. In the exemplary embodiment, a circular ring shape was chosen. However, different ring shapes or different sleeve cross-sections are readily conceivable if they serve the purpose of the contact function.

[0032] The drawings, including the Fig. Figure 4 shows that the contact fingers 15 are curved radially inwards into the plug channel 14 at their origin, i.e., in the area where they connect to the first contact frame 13. Thus, the contact fingers 15 narrow the plug channel 14. At the free end 22 of each contact finger 15, which is furthest from the origin, it is formed radially outwards. In this way, the radially outward-formed free ends of the contact fingers 15 create a kind of insertion funnel for plug extensions 12, which are inserted in the primary plug direction X.

[0033] In the plug connector 10 or plug receptacle 11 shown in the figures, the connecting parts 16, in the form of solder pins 17, are arranged such that the plug channel 14 is free in the secondary plug direction Y. Therefore, a plug extension 12 can also be inserted into the plug channel 14 in the secondary plug direction Y. Insertion in the primary plug direction X means that the plug extension 12 is pushed into the plug receptacle 11 through the second contact frame 18 in the direction of the first contact frame 13. When using the secondary plug direction Y, the plug extension 12 is pushed into the plug receptacle 11 through the first contact frame 13 in the direction of the second contact frame 18. When using the secondary plug direction Y, the contact fingers 15 also form a kind of insertion funnel extending from the first contact frame 13.

[0034] Both insertion funnels (not further specified) meet at the narrowest point of the plug channel 14. The plug channel 14 has its smallest diameter in the plane in which the contact tips 23 of the contact fingers 15 are arranged.

[0035] Fig. Figure 7 shows an enlarged view of a single contact finger 15. This illustration demonstrates how the contact tips 23 of the contact fingers 15 are formed. To produce a contact tip 23 according to the invention, the free end of the contact finger 15 is formed radially outwards along a bending axis B. As mentioned above, this also creates, among other things, the insertion funnel for using the plug receptacle 11 in the primary insertion direction X.

[0036] To form the contact tips 23, the surface of each contact finger 15 facing the insertion channel 14 has two radially outward sloping inclined surfaces 21. These inclined surfaces 21 originate from a common apex line S, which is arranged essentially parallel to the insertion direction. Furthermore, the apex line S is preferably parallel to the longitudinal center axis of the contact finger 15. It can be arranged as a purely geometric line with a radial distance inwards from the contact finger 15 and, in particular, from the forming area at the bending line B. This is the case in the figures and is particularly evident from the illustrations. Fig. 7 clearly visible.

[0037] The contact tip 23 is formed where the apex line S and the bend line B intersect. In a highly preferred embodiment, the bend line divides the inclined surfaces 21 in the insertion direction X and Y approximately in half.

[0038] The bending lines B of each contact finger 15 all lie in a common plane. This plane is preferentially intersected orthogonally by the vertex lines S of each contact finger 15.

[0039] In this way, contact tips 23 are created which are clearly defined in their geometric position in space and ensure an essentially point-like or circular-shaped connection on the plug extension 12.

[0040] Fig. Figure 5 shows the plug receptacle 11 in a bottom view and in the secondary insertion direction Y. It is clearly visible that, in this embodiment, a total of eight contact fingers 15 are used to ensure contact with the plug extension 12 (not shown here). The approximate degree of diameter reduction of the plug channel 14 can also be estimated here. The difference between the maximum inner diameter, defined by the inner diameter of the first contact frame 13, and the minimum inner diameter, defined by the plane of the bending axis B or by the plane in which the contact tips 23 are arranged, is approximately 0.5. This means that the maximum outer diameter is approximately twice the minimum inner diameter. Fig. Figure 6 shows the analogous representation to Fig. 5. This is a top view of the connector 11, i.e. in the direction of the primary insertion direction X.

[0041] Here too, the approximate diameter ratios can be seen, with the diameter of the second contact frame 18 corresponding to that of the first contact frame 13.

[0042] Fig. Figure 1 shows the plug-in extension 12 above the plug receptacle 11, as it is ideally positioned, i.e., inserted into the plug receptacle 11 along its longitudinal center axis in the primary insertion direction X. It is evident that the outer diameter of the plug-in extension 12 is smaller than the inner diameter of both the first and second contact frames 13, 18. It is also evident that the outer diameter of the plug-in extension 12 is larger than the inner diameter of the plug-in channel 14 in the area of ​​the contact tips 23. Consequently, inserting the plug-in extension 12 into the area of ​​the contact tips 23 will cause the contact fingers 15 to deflect elastically. This generates a contact force that holds the contact tips 23 against the plug-in extension 12 to ensure optimal electrical contact.

[0043] As mentioned at the outset, the object of the invention is to improve the pluggability of pluggable extension 12 and plug receptacle 11. This is achieved by allowing certain tolerances in the design of the plug receptacle 11 with regard to the ideal position of the pluggable extension, both with regard to an offset from the longitudinal centerline of the plug receptacle 11 and with regard to an inclination from the longitudinal centerline of the plug receptacle 11.

[0044] As mentioned at the outset, the second contact frame 18 protects the free ends 22 and the contact fingers 15 in general if the plug extension 12 is misaligned too much with the longitudinal centerline of the plug receptacle 11. It was mentioned earlier that this is achieved in particular by the contact frame 18 acting as a guide on the plug extension 12, allowing it to either slide inwards into the plug channel 14 or outwards past the plug receptacle 11. Additionally, it is conceivable that assembly machines used for the automated insertion of the plug extension 12 and plug receptacle 11 could abort the insertion process itself when the plug extension 12 contacts the second contact frame 18 and reposition the plug receptacle 11 and the plug extension 12 relative to each other.

[0045] Apart from such extreme deviations with regard to an offset from the longitudinal center axis of the plug receptacle 11, deviations from the ideal position occur that do not lead to a collision between the plug extension 12 and the first contact frame 18. The funnel-shaped geometry of the contact fingers 15 ensures that the plug extension 12 is still reliably guided into the area of ​​the contact tips 23 even with such tolerated deviations. The selected bending radii R1 and R2 (see Fig. 10) are selected such that even with an offset from the longitudinal centerline, sufficient restoring forces are ensured by radial outward displacement of the contact fingers 15 to guarantee reliable contact even for high-current applications. Such an offset situation is in Fig. Figure 8 shows that the position of the insertion extension 12 deviates from the ideal position in the offset direction V. It is slightly offset to the right with respect to the plane of the drawing. However, it is evident that even in this position, insertion causes the contact fingers 15 to deflect outwards, with the contact fingers 15 on the right side of the drawing plane being deflected somewhat more than the contact fingers 15 on the left side.

[0046] Fig. Figure 9 shows the insertion of the plug-in extension 12 into the plug receptacle 11 at an angle. Here, the longitudinal center axis of the plug-in extension 12 is inclined relative to the longitudinal center axis of the plug receptacle 11. Again, the funnel-shaped design of the contact fingers 15 ensures that the plug-in extension 12 is securely inserted into the area of ​​the contact tips 23. Simultaneously, the bending radii R1 and R2 are selected such that sufficient deflection of the contact fingers 15 is guaranteed to generate sufficient contact forces. In this way, reliable contact with sufficient contact pressure forces is ensured.

[0047] How Fig. As shown in Figure 10, the contact fingers 15 are not bent radially inwards into the insertion channel 14 in their origin region. As a result, the contact finger 15, in particular its obliquely radially inwards section, encloses the angle Alpha with an imaginary sleeve surface.

[0048] The plug receptacle 11 is designed in its basic form for plug-in extensions 12 with a diameter of 3 mm to 4 mm. Depending on the diameter of the plug-in extension, the angle Alpha is 45 to 32 degrees. It is particularly preferred if the contact arms 15 enclose an angle Alpha of 45.5 degrees with the sleeve circumference for a contact extension diameter of 3 mm. For a diameter of 3.2 mm, the angle Alpha is 43.6 degrees. For a diameter of 3.4 mm, an angle Alpha of 40 degrees has proven particularly advantageous. For a diameter of 3.6 mm, an angle Alpha of 36.7 degrees is especially suitable. A diameter of 3.8 mm corresponds to a preferred angle Alpha of 34.5 degrees. For a diameter of 4 mm of the contact extension 12, the invention proposes an angle Alpha of 32.9 degrees for a particularly successful result.

[0049] Depending on the angle Alpha, the radius R2 varies slightly. The radius R1 lies between 0.5 and 1 millimeter, with a radius of 0.6 millimeters being particularly preferred. Reference symbol list 10 plug contacts 11 Plug socket 12 stubby extensions 13 first contact frame 14 plug-in channel 15 contact fingers 16 Connecting part 17 solder pins 18 second contact frame 19 divided bridge 20 undivided bridge 21 inclined surface 22 free ending 23 Contact tip B bending axis S vertex line V Offset direction X Primary connection direction Y Secondary plug direction

Claims

[1] Plug connector (10) with at least one plug extension (12), in particular at least one contact pin and with at least one plug receptacle (11) into which the plug extension (12) can be inserted in the plug-in direction, wherein the plug receptacle (11) is formed by - a first, ring-shaped contact frame (13) which encloses a plug channel (14) for receiving the plug extension (12), - at least one connecting part (16), such as a solder joint or conductor connection on the first contact frame (13), by means of which the plug contact (10) is to be connected to an electrically conductive component, such as a circuit board, stamped grid or connecting conductor, - at least two contact fingers (15) which emerge from the contact frame (13) in the same direction and spring-return elastically into the plug channel (14) to electrically contact the plug extension (12), wherein - each contact finger (15) forms a contact area with which it makes contact with the plug-in extension (12) when the plug-in extension (12) is inserted, and whereby - the plug socket (11) is designed without a support cage, - the contact fingers (15) are only attached to the first contact frame (13) and - the contact forces of the contact fingers (15) are realized exclusively through their inherent elasticity in conjunction with their connection to the contact frame (13), characterized by , that - a second, ring-shaped contact frame (18) is assigned to the first contact frame (13), - the second contact frame (18) is arranged on the first contact frame (13) via at least one bridge (19, 20) oriented parallel to the insertion direction of the insertion extension (12), - the first (13) and second contact frames (18) take the contact fingers (15) between them - the contact fingers (15) are arranged without contact to the second contact frame (18). [2] Plug connector (10) according to claim 1, characterized by , that the contact area of ​​the contact fingers (15) forms a contact tip (23) by each contact finger (15) being curved transversely to the insertion direction of the insertion process (12) and by each contact finger (15) having two inclined surfaces (21) sloping outwards away from the contact channel, which originate from a common vertex line, wherein the contact tip (23) is formed in the area of ​​each contact finger (15) in which the line of curvature and the vertex line intersect. [3] Plug connector (10) according to claim 2, characterized by that the curvature lines of the individual contact fingers (15) lie in a common plane, this plane preferably being aligned parallel to the plane spanned by the ring-shaped contact frame (18). [4] Plug connector (10) according to one of claims 1 to 3, characterized by , that the first (13) and / or the second contact frame (18) act leadingly on the plug extension (12). [5] Plug connector (10) according to one of the preceding claims, characterized by , that the contact fingers (15) arranged only on the first contact frame (13) point with their free ends towards the second contact frame (18). [6] Plug connector (10) according to one of the preceding claims, characterized by , that the plug receptacle (11) is designed as a sleeve-like stamped / bent part made from a sheet metal piece, wherein the butt edges of the sleeve-like shaped sheet metal are located in the area of ​​the web (20) connecting the two contact frames (13, 18). [7] Plug connector according to claim 6, characterized by , that the end edges divide the bridge (19) parallel to the insertion direction, in particular divide it in half. [8] Plug connector (10) according to one of claims 1 to 5, characterized by, that the end edges divide the bridge (19) parallel to the insertion direction, in particular divide it in half. [9] Plug connector (10) according to claim 8 and 6 or 7, characterized by , that the end edges divide the bridge (19) parallel to the insertion direction, in particular divide it in half.

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