SOCKET CONTACT ELEMENT FOR AN ELECTRICALLY CONDUCTIVE CONNECTION

Description

[0001] The invention relates to a socket contact element for establishing an electrically conductive connection, comprising a crimping section for establishing an electrically conductive connection with a cable and a contact box for establishing a detachable electrically conductive connection with a contact box plug.

[0002] Electrical contact elements, contact assemblies, plug-in and detachable cable connection elements, and suitable manufacturing processes are available in the known art. Socket or contact elements can be designed as crimp contacts. In connection technology for electrical contacting tasks, crimp contacts are designed as elements with tabs, the ends of which are bent around the electrical conductor and simultaneously pressed together with it. This available connection technology is referred to as crimping. The necessary forming and pressing processes are often impressed on a prepared semi-finished product, which is available as an uncrimped or pre-crimped starting material and which later forms the contact element. To carry out the crimping, the semi-finished product is often placed on the anvil of a crimping tool. The electrical conductor or contact element is thenA stripped section of the electrical conductor is placed on the contact element. Then, at least one crimp tab is bent around the stripped section and pressed against it to create a mechanically stable and electrically conductive contact between the contact element and the electrical conductor.

[0003] Depending on the area of application, crimp connections must meet different, sometimes cumulative, requirements - examples: mechanical strength, fatigue strength, low-resistance transmission of electrical energy, corrosion resistance, gas and liquid tightness.

[0004] In addition to crimp contacts, with their functional task of connecting supply lines, cables, or similar – usually live – conductors to contact elements, contacting components must meet a multitude of additional requirements. For this reason, in addition to the crimp connection areas, there are other body-like components within the contacting components, which are implemented either integrated or separately. Examples include clamping and guiding elements, sockets, connectors, etc.

[0005] Known methods for producing contact components include, in particular, punching and forming processes. First, a flat part is separated from a sheet of material by a punching or, more generally, a separation step. The flat part is then appropriately provided with contours that support its shaping into the contact element and its defined functions. The flat semi-finished product thus produced is then further developed in one or more forming steps. Possible forming processes can be realized by folding, bending, pressing, deep drawing, or similar processes.

[0006] The document DE 10 2015 201 635 A1 shows a complex contact that has an asymmetrical contact box and requires complex punching tools.

[0007] Other manufacturing options for contacting elements can be achieved through sintering processes, additive manufacturing processes or through machining or chip removal.

[0008] Although the combination of punching and forming of a sheet-shaped starting material is an economical and reliable way to provide contacting components in large quantities, the restricted geometric shape limits the integration of various functions into one-piece contacting components and in particular socket contact elements.

[0009] To mitigate this disadvantage, the integrally implemented functions are limited or reduced to reduce the complexity of the component and / or the contact components are designed in multiple parts. Additive manufacturing processes such as 3D printing or stereolithography are also considered, but these are only suitable for mass production to a limited extent, are economically disadvantageous, and are limited in terms of processable materials.

[0010] It is an object of the invention to at least partially reduce the aforementioned disadvantages and to provide a one-piece socket contact element with a plurality of integrative functions.

[0011] To achieve this, the invention proposes a socket contact element for establishing an electrically conductive connection with a crimping section for establishing an electrically conductive connection having the features of claim 1.

[0012] The invention recognizes that the geometric complexity of the flat material as a semi-finished product for one-piece socket contact elements and / or the appropriate forming sequence are suitable for increasing the number of integral functions. In individual cases, the invention also takes into account elastic material properties and the resulting forming and punching process results with regard to burr formation and oblique punching edges in the direction of the flat thickness.

[0013] A further aspect of the invention is to adapt the geometric contour of the semi-finished product as a result of the punching process both with regard to the achievable dimensional accuracies and the - preferably metallic and / or at least electrically conductive - material properties with regard to deformability, elasticity and strength.

[0014] The invention is explained in more detail below using a preferred embodiment in conjunction with the figures. In the figures: Fig. 1a, 1b show the first and second perspective views of an exemplary embodiment of the socket contact element; Fig. 2a, 2b show the third and fourth perspective views of an exemplary embodiment of the socket contact element; Fig. 3a, 3b show the fifth and sixth perspective views of an exemplary embodiment of the socket contact element; Fig. 4a, 4b each show a perspective view of the contact box of an exemplary embodiment of the socket contact element; Fig. 5a, 5b show a first side view and a first plan view of the exemplary embodiment of the socket contact element; Fig. 6a, 6b show a second side view and a second plan view of the exemplary embodiment of the socket contact element; Fig. 7a, 7b show a first and a second end view of the exemplary embodiment of the socket contact element; Fig. 8a, 8b each show a sectional view of the contact box of an exemplary embodiment of the socket contact element; Fig.9a, 9b the first perspective sectional view of an exemplary embodiment of the socket contact element as a whole and its contact box; Fig. 10a the second perspective sectional view of an exemplary embodiment of the socket contact element as a whole and its contact box; Fig. 10b the second perspective sectional view of an exemplary embodiment of the socket contact element includes the detail of the contact box; Fig. 11a the sectional view AA of the contact box of the socket contact element at the level of the closure tab with stop; Fig. 11b the sectional view BB of the contact box of the socket contact element at the level of the locking hook head of the locking hook; Fig. 12a the sectional view CC of the contact box of the socket contact element at the level of the support nose of the closure tab with locking hook; Fig. 12b the sectional view DD of the contact box of the socket contact element at the level of the closure tab and contact zone; Fig.Fig. 13: the sectional view EE of the contact box of the socket contact element at the level of the locking tab with spring lip; Fig. 14: the top view of a first example of the curved, one-piece flat material as a semi-finished product after a stamping process before forming by bending or folding; Fig. 15: the top view of a second example of the curved, one-piece flat material as a semi-finished product.

[0015] Figure 1a and Figure 1b depict a first and second perspective view of an exemplary embodiment of the socket contact element 100. The preferably one-piece element extends in the direction of a longitudinal axis L, which in regions of a symmetrical design is equal to the symmetry or center axis M. The invention provides that integral functions are realized by and optionally within regions. In Figure 1the socket contact element 100 is shown with a plurality of regions 10, 20, 30, 40, 50, 60, 70, the juxtaposition of which is realized in a longitudinal extension.

[0016] Figure 2a and Figure 2b form a third and fourth as well as Figures 3a and 3b a fifth and sixth three-dimensional view of an exemplary embodiment of the socket contact element 100.

[0017] Figure 4a and Figure 4b Each illustrates a perspective view of the contact box 70 of an exemplary embodiment of the socket contact element 100. In the example shown, the contact box 70 has a plurality of integrally implemented functions. In particular, guide and spring elements are provided on both the outside and inside.

[0018] On the outside of the square geometry of the contact box 70, an orientation lip 71 is provided, which has a threading bevel, insertion chamfer 71a, in the insertion direction of the socket contact element 100 into, for example, a contact carrier or multi-contact block. The orientation lip 71 interacts geometrically with a correspondingly designed receiving bore of a contact carrier or multi-contact block in such a way that assembly in only one correctly oriented position is enforced. The orientation lip 71 can be supplemented by a lug 71b on the longitudinal end face and opposite the insertion direction EK of the contact box 70. The lug 71b can, for example, functionally interact with a spring element of the contact carrier or multi-contact block or be used as a rear grip. Furthermore, a bore 71c can be provided for receiving a locking lug 72a of the locking tab 72.

[0019] To form the square geometry of the contact box 70, at least one closure tab 72 is further provided, which is brought into position about a fold line parallel to the longitudinal axis L by a forming process, also called folding or beveling. By means of a closure lug 72a or a contoured closure lug 72b, a rear engagement in a corresponding recess in the side wall of the contact box 70 or bore 71c of the orientation lip can support the defined positional fixation of the closure tab 72. The contoured closure lug 72b is preferably formed with its contoured part opposite the insertion direction EK of the contact box 70 in order to avoid forming edges in the insertion direction, which could be the cause of insertion problems of the contact box 70 into contact carriers or multi-contact blocks.

[0020] Depending on the position and number of integrated functions, a closure tab 72 can be supplemented by a support lug 72c, which can be geometrically comparable to the closure lug 72a and, due to its design, represents a support shoulder on a side wall end face of the contact box 70 and rests thereon. In this way, the strength and structural integrity of the overall construction are increased and a simple movement limitation during the forming process is provided.

[0021] A locking hook 73 designed as a spring element with its locking hook end aligned opposite to the insertion direction EK of the contact box 70 serves to fix the position of the contact box 70 in the longitudinal direction after insertion into the contact carrier or multi-contact block. The locking hook head 73a can, as shown, have radially projecting wings that correspond to a recess in the contact carrier or multi-contact block or provide a tool engagement surface to assist in bending back the locking hook 73 and thus disassembly of the contact box 70 from the contact carrier or multi-contact block. Alternatively, the locking hook 73 can taper to a blunt end if disassembly is not to be supported. To specifically influence the spring properties and spring or restoring force, the locking hook tongue can be tapered towards the locking hook head.

[0022] Figure 5ashows a first side view of the exemplary embodiment of the socket contact element 100.

[0023] Figure 5b shows the first plan view of the exemplary embodiment of the socket contact element 100 analogous to Figure 5a Preferably, a handling section 10 is provided at the end, which is formed by a section of the flat material and has a central region with a bore 11 adjacent to the longitudinal axis L and at least one surface piece 12 in the radial direction of extension. A notch 13 can optionally be provided in the radial end direction of the handling section 10, for example, for implementing a spring element or as a wraparound for an adjacent flat in the assembled state.

[0024] Figure 6adepicts a second side view of the exemplary embodiment of the socket contact element 100. While the contact box 70 and the crimping section 50 are arranged in alignment in the longitudinal direction to the center axis L, M, the insulating section 30 and the handling section 10 can have an offset parallel to the axis. This offset is realized by the deflection of the second connecting section 40 and / or the third connecting section 60. This offset is particularly advantageous with regard to the cable routing in the crimping section 50 and the insulating section 30, since kinking of the cable core is avoided. This is achieved by selecting the offset according to the wall thickness of the insulating material surrounding the cable core of the cable.

[0025] The insulation section 30 integrates a mechanical stress relief function for the crimp section into the socket contact element 100 in that the mechanical loads—particularly tension—acting on a damaged cable (not shown) are absorbed by the insulation section 30 and thus cannot act on the crimp section 50. The insulation section can therefore also be called a strain relief section.

[0026] Figure 6b shows the second top view of the exemplary embodiment of the socket contact element 100 analogous to Figure 6a While the insulated wire can be arranged in the receiving space 31 of the insulation section 30, the wire core (stripped wire) will be located in the receiving space 51 of the crimping section 50. As a result, the wire to be crimped with the socket contact element 100 (not shown) can be secured both in alignment with the longitudinal axis L, M and with a largely reduced kinking.

[0027] Figure 7a shows the first end view of the exemplary embodiment of the socket contact element 100 at the end of the contact box 70 with its receiving space 70a for a contact box plug. The square space can have a square shape as shown; unequal side edges are also possible.

[0028] Figure 7b shows the second end view of the exemplary embodiment of the socket contact element 100 at the end of the handling section 10.

[0029] Figure 8a and Figure 8b each comprise a sectional view of the contact box 70 of an exemplary embodiment of the socket contact element 100. The interior of the contact box 70 designed as a receiving space 70a for a contact box plug reveals further, integrally implemented functions of the invention.

[0030] Figure 8ashows the sectional view of the contact box 70 with its side facing away from the orientation lip 71. Within the contact box 70, the receiving space 70a is designed for an insertable contact box plug, which can be physically and in particular electrically contacted with the contact box 70 at least in a contact zone 70b. While the side walls of the contact box 70 functionally provide the linear lateral guidance for the contact box plug (not shown) to be inserted in the insertion direction ES, the contact zone 70b is formed or spatially delimited by a spring lip 74 and a contact arch 75.

[0031] In the present embodiment, the contact zone 70b is designed symmetrically or axially symmetrically to the center axis L, M in the state of the inserted contact box plug.

[0032] The clear width of contact zone 70b is undersized relative to the contact box connector without the inserted contact box connector, so that inserting the contact box connector causes the spring lip 74 to deflect against its spring force, releasing the clear width required for the contact box connector. The restoring force of the spring lip 74 presses the contact box connector at its contact surface 74a against the contact surface 75a of the contact arch 75.

[0033] The contact surfaces 74a, 75a are partially designed as cylindrical surfaces, so that the following functional properties are supported: The contact surfaces 74a, 75a each form a linear contact surface compared to a flat contact box plug, the linear contact surfaces are comparatively small in size so that an increased surface pressure can be achieved, the increased surface pressure results in reliable contact behavior of the contact partners to one another, the design of the contact surfaces 74a, 75a as cylinder jacket sections supports easier threading and insertion of the contact box plug into the receiving space 70a and reduces the linear breakaway force when decontacting by pushing out the contact box plug against the direction ES.

[0034] Figure 8bshows the sectional view of the contact box 70 with its side facing the orientation lip 71. In order to mechanically limit the insertion depth of the contact box plug into the receiving space 70a of the contact box 70, the invention provides a stop 76 in the insertion direction ES at the front and end of the contact box 70. The stop can be designed as a flange or nose, thus forming a physical stop element for the contact box plug.

[0035] Figure 9a comprises the first perspective sectional view of an exemplary embodiment of the socket contact element 100. The sectional plane arranged vertically at the height of the longitudinal or central axis L, M shows further functions or geometric configurations that are preferably implemented in one piece or integrally.

[0036] Figure 9b illustrates the contact box 70 in the perspective sectional view as a detail from Figure 9aIn this embodiment, integral functions are realized in the locking tabs 72. The first locking tab 72, arranged in the insertion direction of the contact box plug ES, is integrally supplemented by the spring lip 74 with its contact surface 74a in the region of the cylindrical end section. The width of the spring lip 74 and its contact surface 74a is selected to be less than the clear width of the receiving space 70a for the contact box plug (not shown). The same applies to the width of the contact arch 75 with its contact surface 75a.

[0037] The second locking tab 72 arranged in the insertion direction of the contact box plug ES is one-piece and is supplemented in the direction of ES by the locking hook 73 with its locking hook head 73a.

[0038] The third locking tab 72 arranged in the insertion direction of the contact box plug ES is one-piece and is supplemented in the direction of ES by the stop 76.

[0039] Figure 10a comprises the second perspective sectional view of an exemplary embodiment of the socket contact element 100 and Figure 10b the contact box 70 in the perspective sectional view as a detail from Figure 10a .

[0040] Figure 11a shows the sectional view AA of the contact box of the socket contact element 100 at the level of the locking lug 72a of the locking tab 72 with stop 76. The locking lug 72a engages in the bore 71c of the orientation lip 71 and practically functions as an abutment to the folded edge, bending hinge 72d, so that increased structural stability is supported.

[0041] Figure 11b includes the sectional view BB of the contact box 70 of the socket contact element 100 at the level of the locking hook head 73a of the locking hook 73.

[0042] Figure 12ashows the sectional view CC of the contact box 70 of the socket contact element 100 at the level of the support lug 72c of the locking tab 72 with the locking hook 73. Again, the invention utilizes the stability-enhancing effect of the abutment formed by the support lug 72c with respect to the beveled, bending hinge 72d. The spring lip 74 and the contact arch 75 extend at this sectional height within the receiving space for the contact box plug 70a.

[0043] Figure 12bdepicts the sectional view DD of the contact box 70 of the socket contact element 100 at the level of the locking tab 72 with contact zone 70b. The contact zone 70b is located in the area of the smallest clear width formed by the contact surfaces 74a, 75a of the spring lip 74 and the contact arch 75. Shown here is the spherical contour of the contact surfaces 74a, 75a. This geometrically caused functional integration results in a reduced contact surface with the contact box plug (not shown), so that an increased surface pressure occurs with an otherwise unchanged spring force of the spring lip 74.

[0044] Figure 13 shows the sectional view EE of the contact box 70 of the socket contact element 100 at the level of the closure tab 72 with spring lip 74. Shown is a left-hand bend 72d of this closure tab 72, which is opposite to the bend 72d of the closure tab 72 with locking hook 73 made of Figures 12a and 12bThe invention recognizes that the arrangement of opposing bends 72d is suitable for supporting one-piece production by forming from a semi-finished flat.

[0045] Figure 14 shows a top view of a first example of the arc-shaped, one-piece flat material 100' as a semi-finished product after a stamping process before forming by bending and folding. After its pre-assembly, the contoured flat material 100' serves as the starting material for introducing the crimp contour in the crimp section 50 and forming the contact arc 75 in the subsequent contact zone 70b. Bulk forming processes are typically performed for this purpose.

[0046] The deformation processes for forming the socket contact element 100 can be roughly divided into three zones of the semi-finished flat 100': The central area MB between and the two adjacent outer areas.

[0047] The central region MB is not deformed or is only marginally deformed in the handling area 10 and in the area of the contact box 70, so that a substantially flat structure is maintained. In the other areas, a spherical or spatial deformation of varying degrees occurs, for example, in the shape of a cylindrical segment.

[0048] The respective outer regions can be subjected to bending measures, folding processes, or free forming. In particular, in the region of the contact box 70, bending and folding sequences can be provided in order to establish the correct positions of the locking hook 73 outside the later receiving space 70a for the contact box plug and of the spring lip 74 within the later receiving space 70a for the contact box plug. In the present exemplary embodiment, this specifically means that, by a first folding or bending process, the closure tab 72 with spring lip 74 is first formed into its final position, followed by the forming process for the closure tab 72 with locking hook 73. The closure tab 72 with stop 76 is not subject to any sequence constraints and can be formed at any time from the semi-finished product arc plane into the final position to form the contact box 70 of the socket contact element 100.

[0049] Figure 15illustrates the top view of a second example of the curved, one-piece flat material 100'. While the geometric configurations of the contact box 70 are comparable to the situation depicted by Figure 14 are has shows the Figure 15 a flat with a modified geometry in the first connecting section 20, insulation section 30, second connecting section 40, crimping section 50 and third connecting section 60. List of reference symbols

[0050] 10Handling section 11Hole, eyelet 12Surface piece in radial direction of extension 13Notch 20First connection section 30Insulation section 31Accommodation for cable 40Second connection section 50Crimp section 51Accommodation for stripped cable, core 60Third connection section 70Contact box 70aAccommodation for contact box plug 70bContact zone 71Orientation lip 71aThreading bevel, insertion chamfer 71bNose 71cHole 72Locking tab 72aLocking nose 72bContoured locking nose 72cSupport nose 72dFold, bending hinge 73Locking hook 73aLocking hook head 74Spring lip 74aContact surface 75Contact bend 75aContact surface 76Stop 100Socket contact element 100'Semi-finished product, flat EKInsertion direction of the contact box ESInsertion direction of the contact box plug LLongitudinal axis MMiddle axis MBCenter area

Claims

1. Socket contact element (100) for establishing an electrically conductive connection, having a crimp section (50) for establishing an electrically conductive connection to a line and having a contact box (70) with a square cross section and a square geometry for establishing a releasable electrically conductive connection to a contact box plug, wherein the socket contact element (100) is of one-part construction and comprises a plurality of functional sections, wherein the contact box (70) has at least one latching hook (73), which supports locking in the receiving bore of a contact carrier or multi-contact block and is designed in a manner tapering towards the latching hook head for influencing the spring property and spring or return force in a targeted manner, characterized in that a side wall of the contact box (70) forms an orientation lip (71) for orienting the socket contact element (100), which orientation lip extends beyond the box-like structure of the contact box (70) and has a lug (71b), which is arranged on the longitudinal end face of the orientation lip (71) and extends opposite to the insertion direction (EK) of the contact box (70).

2. Socket contact element (100) according to Claim 1, characterized in that the socket contact element (100) is supplemented by a handling section (10).

3. Socket contact element (100) according to Claim 1, characterized in that the socket contact element (100) has an insulation section (30).

4. Socket contact element (100) according to Claim 3, characterized in that the insulation section (30) is arranged relative to the crimp section (50) in such a way that a largely straight arrangement of the core of a line to be received is supported.

5. Socket contact element (100) according to Claim 1, characterized in that the contact box (70) is supplemented by at least one closure tab (72) at least in one side surface.

6. Socket contact element (100) according to Claim 5, characterized in that the at least one closure tab (72) is supplemented by a closure lug (72a) corresponding to at least one side wall of the contact box (70) and / or a contoured closure lug (72b), so that the structural integrity of the contact box (70) is supported.

7. Socket contact element (100) according to Claim 6, characterized in that the closure lug contouring (72b) is formed opposite to the insertion direction of the contact box EK and engages into a corresponding recess within the contact box (70).

8. Socket contact element (100) according to Claim 1, characterized in that the contact box (70) surrounds an interior at least in regions, so that a receiving space (70a) for a contact box plug and / or a contact zone (70b) is formed.

9. Socket contact element (100) according to any of the preceding claims, characterized in that the at least one latching hook (73) and / or the at least one spring lip (74) and / or the stop (76) are / is formed in one piece with in each case one closure tab (72).

10. Socket contact element (100) according to Claim 9, characterized in that the at least one spring lip (74) is formed in a manner tapering towards the spring lip tip.