CONTACT ELEMENT, PLUG CONNECTION UNIT AND CONTROL UNIT

Description

State of the art

[0001] The invention relates to a plug connection unit with at least two contact elements according to the preamble of claim 1 and to a control device with such a plug connection unit.

[0002] A contact element is known from DE 10 2014 203 248 A1, filed by the applicant. The contact element, arranged in a control unit, serves as a connection between a circuit carrier and a connector, in particular a cable harness connector, which can be connected to the control unit in the region of a connector body of the control unit. The known contact element has a first subsection with a press-in section, which forms an electrical contact with an opening in the circuit carrier. On the side facing away from the first subsection, the contact element forms a second subsection, which can be connected to a corresponding element of the connector as a counter element.

[0003] In practice, several rows, each with a plurality of such contact elements, are provided in the area of ​​the plug connector body, forming a so-called "male connector." To press in the press-in section of the contact element, the contact element has one or two press-in shoulders at a relatively short distance from the press-in section. These press-in shoulders interact with a corresponding tool that applies an axial force in the longitudinal direction of the press-in section to press the contact element into the opening of the circuit carrier. Due to manufacturing and assembly tolerances, such a press-in process is all the more critical the smaller the cross-section of the contact element between the press-in section and the at least one press-in shoulder and the greater the axial distance between the press-in section and the at least one press-in shoulder (buckling).

[0004] Furthermore, data lines in the form of Ethernet cables are known from the prior art, in which two contact elements arranged next to each other are provided to connect the data line, for example, to a control unit. The two contact elements typically have a standardized spacing of approximately 1.8 mm.

[0005] From published patent application DE 10 2012 218 433 A1, a contact arrangement comprising a contact element is known, wherein the contact element has a press-in section arranged at a first longitudinal end. This press-in section is designed to be pressed into the printed circuit board. Furthermore, the contact element has a contact section arranged at a second longitudinal end of the contact element opposite the first longitudinal end. In particular, the contact arrangement also has precisely one shoulder section arranged between the contact section and the press-in section, protrudes laterally relative to the contact section, and is designed to introduce a press-in force Fp into the press-in section. Disclosure of the invention

[0006] The plug connection unit according to the invention with a contact element for forming an electrical connection between a circuit carrier in a control unit and a plug with the features of claim 1 has the advantage that it enables secure assembly or secure pressing of the contact element even with a relatively large axial distance between the press-in section and the at least one press-in shoulder of the contact element. Furthermore, the plug connection unit according to the invention makes it possible, in particular for forming data lines in which two contact elements interact, to form a reduced distance between the second subsections serving to contact the counter-elements of the data line compared to the press-in areas.

[0007] The plug connection unit is based on the assumption that it comprises a plug connection body made of plastic, which partially surrounds at least two contact elements. Such a contact element has a first partial section with a press-in section for pressing into an opening in the circuit carrier. Furthermore, such a contact element has at least one press-in shoulder arranged at a distance (L) from the press-in section for applying a press-in force aligned in the direction of a first longitudinal axis of the first partial section. Furthermore, such a contact element has a second partial section having a second longitudinal axis for contacting the line, wherein the contact element is designed as a stamped element made of sheet metal. The longitudinal axes of the two partial sections of a contact element are arranged parallel and laterally offset from one another.The cross-section of the first sub-section (which has the press-in section) is larger than the cross-section of the second sub-section (which interacts with a counter-element or a line of the plug). Furthermore, the at least one press-in shoulder forms an end face of the first sub-section on the side facing away from the press-in section, wherein the second sub-section extends from or originates from the end face of the first sub-section. Because the sub-section having the press-in section has a larger cross-section than the second sub-section facing the plug, the tendency of the first sub-section to kink is reduced and the mechanical rigidity of the contact element in the relevant area is increased.Furthermore, the lateral offset of the two sections in conjunction with the reduced cross-section of the second section makes it possible to arrange two contact elements with their two interacting second sections in such a way that they have a reduced distance compared to the first sections, which reduces the effect of electromagnetic radiation when used as part of a data line and thus increases data transmission security.

[0008] In order to enable such a contact element to be contacted in a direction perpendicular to the circuit carrier by a counter element of a plug that interacts with the contact element, it is further provided that the contact element is flat.

[0009] The plug connection unit further comprises a plastic plug connection body having at least two contact elements as described above, with the plastic of the plug connection body partially surrounding the contact elements. The plug connection unit is characterized in that the plastic of the connector connection body, on the side facing away from the press-in section, runs at least approximately flush with the end face of the first subsection. This makes it possible to arrange a corresponding tool in the region of the press-in shoulder of the contact element when pressing the contact element into the corresponding opening in the circuit carrier, which tool simultaneously rests against the plastic of the plug connection body.This also makes it possible to place lower demands on the positioning accuracy of the corresponding press-in tool and has the additional advantage that the press-in force can also be introduced into the contact element via the plastic of the plug connection body.

[0010] In order to be able to transmit the corresponding press-in forces particularly reliably into the contact element via the plastic of the plug connection body, it is also advantageous if the plastic of the plug connection body surrounds at least one holding section of the contact element.

[0011] To form a data line, in particular an Ethernet line, it is further provided that two longitudinal axes of two adjacent first sections of two contact elements have a first distance from one another which is greater than a second distance between the two longitudinal axes of the second sections.

[0012] In order to be able to mechanically connect the contact element, which is partially overmolded by the plastic of the plug connection body, to the plug connection body in a particularly strong manner, it is provided that the first section of the contact element, viewed in the longitudinal direction, has at least one laterally projecting holding section between the press-in section and the at least one press-in shoulder. Since, in the installed state of the contact element, it is thus surrounded by the plastic of the plug connection body in the axial region between the press-in shoulder and the at least one holding section, the rigidity of the contact element is further increased or increased in this axial section.

[0013] It is particularly preferred if at least two holding sections are provided, which are arranged at an axial distance from one another relative to the longitudinal axis of the first partial section of the contact element. This creates an undercut between the two holding sections, which can be filled by the plastic of the plug connection body, thus forming a positive connection between the holding sections and the plastic of the plug connection body.

[0014] Furthermore, in a further preferred embodiment of the plug connection unit, it is provided that a contact element has a single press-in shoulder which, with the exception of the area from which the second sub-section originates, forms the end face of the first sub-section for the application of the press-in tool.

[0015] To further enable a (data) line that is robust against the coupling of electromagnetic radiation, it is advantageous if, in addition to the two contact elements forming the data line, at least one further contact element is provided to form a ground connection with the connector. This enables a ground connection on the control unit side to a shielding housing for the (data) line located in the connector.

[0016] Furthermore, it can be provided that, in order to protect the cable from penetrating media or moisture, a plug contact carrier has a chamber for accommodating a plug-side sealing element.

[0017] Finally, the invention also includes a control device with a circuit carrier and a plug connection unit connected to the circuit carrier.

[0018] Further advantages, features and details of the invention will become apparent from the following description of preferred embodiments and from the drawings.

[0019] This shows in: Fig. 1 shows a perspective view of two contact elements arranged side by side, which form a part of an Ethernet connection in a control unit, Fig. 2 shows a plug contact carrier placed on a plug connection unit for use with a circuit carrier in a control unit, Fig. 3 shows a perspective longitudinal section through a plug-in system in a simplified view, and Fig. 4 shows a part of the plug-in system of the Fig. 3 in enlarged, perspective view.

[0020] Identical elements or elements with the same function are provided with the same reference numbers in the figures.

[0021] In the Fig. 1 Two contact elements 10 are shown, as they serve as a component of an electrical contact between a control unit 100 and a connector 1000, in particular a connector 1000 of a wiring harness of a motor vehicle. Fig. 3 shows a circuit carrier 2, in particular in the form of a printed circuit board, with openings 1. The circuit carrier 2 is arranged within a housing (not shown) of the control unit 100. Furthermore, a plug connection body 60 is shown, which carries the contact elements 10 and which can be contacted with the plug 1000.

[0022] The contact element 10 is designed as a stamped component made of sheet metal and has two sections 11, 12. The first section 11, which, like the second section 12, is essentially straight or pin-shaped, has a press-in section 14 with an enlarged cross-section, which is designed to cooperate with the corresponding opening 1 of the circuit carrier 2 by pressing the press-in section 14 into the opening 1 in the direction of the longitudinal axis 15 of the first section 11. The circuit carrier 2 has an electronic circuit (not shown) which is electrically contacted with the opening 1, for example via conductor tracks. Fig. 3 the circuit carrier 2 and the contact elements 10 or the plug connection body 60 are shown in the unjoined state.

[0023] Adjoining the press-in section 14 on the side facing the circuit carrier 2 or the opening 1 is an insertion section 16 which is pointed or has a reduced cross-section in order to facilitate the insertion of the first sub-section 11 or the contact element 10 into the opening 1 of the circuit carrier 2. On the side opposite the insertion section 16, an end face 18 of the first sub-section 11 forms a press-in shoulder 20 at a distance L from the press-in section 14. In the area of ​​the press-in shoulder 20, the first sub-section 11 has a width B which is greater than a width b between the press-in shoulder 20 and the press-in section 14, the cross-section of the first sub-section 11 being rectangular.

[0024] At an axial distance from the press-in shoulder 20 relative to the first longitudinal axis 15, two holding sections 21, 22 are located on opposite sides, projecting perpendicularly from the longitudinal axis 15 and approximately rectangular in side view. Furthermore, a further holding section 23 is arranged just below the press-in shoulder 20 on one side.

[0025] The second section 12 of the contact element 10, which is also rectangular in cross-section, adjoins the press-in shoulder 20 in the axial direction, extending from the height of the press-in shoulder 20 from the first section 11. Furthermore, the second section 12 is extended in the direction of the holding section 22 and forms a further holding section 24. A distance x is formed between the holding sections 21, 22 and 23, 24.

[0026] The second section 12 serves to form an electrical connection with a counter element of the plug 1000, wherein the cross section of the second section 12 is smaller than the cross section of the first section 11 in a central section 25 between the holding sections 21, 22 and the press-in section 14. Furthermore, based on the Fig. 1 It can be seen that an offset s is formed between the first longitudinal axis 15 of the first sub-section 11 and a second longitudinal axis 26 of the second sub-section 12.

[0027] The two in the Fig. 1 The contact elements 10 shown, arranged side by side, which serve to form a contact for an Ethernet line or data line 5, have a distance A of approximately 2.54 mm in the region of the two first longitudinal axes 15 of the first sub-sections 11, wherein the distance A also corresponds to the distance between the openings 1 in the circuit carrier 2, and wherein the distance A corresponds to a standardized dimension or a pitch, as is usually used for circuit carriers 2 or printed circuit boards. In contrast, the two second longitudinal axes 26 in the region of the second sub-sections 12 have, for example, a distance a of approximately 1.8 mm, wherein the distance a is selected depending on the data line 5, which in this regard also has standardized dimensions or pitch dimensions in the region of the contact elements for the contact elements 10.

[0028] To press in a contact element 10, a press-in tool (not shown) is brought into operative connection with the press-in shoulder 20 in such a way that the press-in force is transmitted to the contact element 10 in the direction of the first longitudinal axis 15.

[0029] In the Fig. 2 , a plug connection unit 50 made of plastic by injection molding is shown, comprising a plug connection body 60 which is placed on a plug contact carrier 61, wherein the plug connection body 60 partially surrounds several contact elements 10. Fig. 2 In addition, the press-in sections 14 can be seen, which interact with the openings 1 in the circuit carrier 2 of the control unit 100. In the illustration of the Fig. 2 Both analog lines 4 of the connector 1000 and a data line 5 in the form of an Ethernet line are also visible. The data line 5, as well as the power supply lines 6, are partially surrounded by the plastic of the connector contact carrier 61, wherein a radially surrounding receiving space 62 is formed, into which a connector-side, in the Fig. 4 recognizable sealing element 7, 8 of the data line 5 or the line 6 can be inserted.

[0030] According to the presentation of the Fig. 4 In the area of ​​the connector 1000, a shielding housing 66 is provided to shield the data line 5. Furthermore, Fig. 4 It can be seen that the plastic of the plug connection body 60 surrounds the area of ​​the contact element 10 up to the level of the press-in shoulder 20, ie that the contact element 10 is positively surrounded or overmolded by the material of the plug connection body 60, in particular in the area between the holding sections 21 to 23 and the press-in shoulder 20.

[0031] The shielding housing 66 in the plug 1000 interacts through contact with a ground contact designed as a further contact element 68, which is arranged in contact with the shielding housing 66 when the plug 1000 is connected to the plug connection body 60. The further contact element 68, like the contact element 10, is designed as a flat contact element 68 and is partially overmolded with the material of the plug connection body 60. The further contact element 68 also has a press-in section 70, with which it is electrically contacted in a corresponding opening 1 in the circuit carrier 2, this opening 1 being electrically at ground potential.

[0032] According to the presentation of the Fig. 4 In the area of ​​the plug connection body 60 or the plug connection unit 50, two rows 71, 72 with contact elements 10 or further contact elements 68 arranged next to one another are provided, for example.

[0033] The contact element 10 described so far as well as the control unit 100 and the connector 1000 can be modified or altered in a variety of ways.

Claims

1. Plug connection unit (50), having a plug connection body (60) which consists of plastic and surrounds at least two contact elements (10) in regions, wherein each contact element (10) is designed to form an electrical connection between a circuit carrier (2) in a control device (100) and a line (4 to 6) in a plug (1000), wherein each contact element (10) is designed with a first sub-section (11), which has a press-in section (14) to be pressed into an opening (1) in the circuit carrier (2), with at least one press-in shoulder (20), which is arranged at a distance (L) from the press-in section (14), for applying a press-in force oriented in the direction of a first longitudinal axis (15) of the first sub-section (11), and with a second sub-section (12), which has a second longitudinal axis (26), for contacting the line (4 to 6), wherein each contact element (10) is flat and designed as a punched element composed of sheet metal, wherein the longitudinal axes (15, 26) of the two sub-sections (11, 12) are arranged parallel and with a lateral offset (s) in relation to each other, wherein the cross section of the first sub-section (11) between the press-in section (14) and the at least one press-in shoulder (20) is larger than the cross section of the second sub-section (12), and that the at least one press-in shoulder (20) forms an end side (18) of the first sub-section (11) on the side averted from the press-in section (14), wherein the second sub-section (12) starts from the end side (18), characterized in that the plastic of the plug connection body (50), on the side averted from the press-in section (14), runs at least approximately flush with the end side (18) of the first sub-section (11) in such a way that each contact element is simultaneously supported on the plastic of the plug connection body under the action of a press-in force, so that the press-in force can additionally be introduced into the contact element via the plastic of the plug connection body, and that two longitudinal axes (15) of two first sub-sections (11) which are adjacent to each other in the same metal sheet plane are at a first distance (A) from each other, this distance being greater than a second distance (a) between the two longitudinal axes (16) of the second sub-sections (12).

2. Plug connection unit according to Claim 1, characterized in that the first sub-section (11), as viewed in the direction of the first longitudinal axis (15), has at least one laterally protruding holding section (21 to 24) between the press-in section (14) and the at least one press-in shoulder (20).

3. Plug connection unit according to Claim 2, characterized in that at least two holding sections (21 to 24) are provided, which are arranged spaced apart from each other by a distance (x) in the direction of the first longitudinal axis (15) of the first sub-section (11).

4. Plug connection unit according to any of Claims 1 to 3, characterized in that a single press-in shoulder (20) is provided, which forms the end side (18) of the first sub-section (11), except for the region from which the second sub-section (12) starts.

5. Plug connection unit according to Claim 1, characterized in that the plastic of the plug connection body (60) surrounds the at least one holding section (21 to 24) at least in regions.

6. Plug connection unit according to Claim 1, characterized in that the first and the second distance (A, a) are standardized distances for forming connections of data lines (5) and press-in connections in circuit carriers (2).

7. Plug connection unit according to Claim 1, characterized in that the first distance (A) is approximately 2.54 mm and the second distance (a) is approximately 1.8 mm.

8. Plug connection unit according to Claim 1 or 7, characterized in that at least one further contact element (68) for forming an earth connection is provided for forming a data line (5) shielded against electromagnetic radiation.

9. Plug connection unit according to Claims 6 to 8, characterized in that at least one cavity (64) for receiving a sealing element (7, 8) for a data line (5) is formed in a plug contact carrier (61).

10. Control device (100), comprising a circuit carrier (2) and a plug connection unit (50) which is connected to the circuit carrier (2) and is designed according to any of Claims 1 to 9.

11. Control device according to Claim 10, characterized in that two adjacent contact elements (10) are constituent parts of, or contact, a data line (5), preferably an Ethernet line.