ELECTRIC CONNECTOR

Description

TECHNICAL AREA

[0001] The present invention relates to electrical connectors for connecting wires to an electrical circuit, printed circuit board, or assembly. The invention further relates to a method for connecting a wire. TECHNICAL BACKGROUND, STATE OF THE ART

[0002] The task of electrically connecting wires to a circuit, circuit board, assembly, or similar device arises in many areas of electrical engineering in a wide variety of forms. In addition to electrical and mechanical reliability during operation, the requirements generally include simple assembly and, if necessary, disconnection of the connection, error-free handling, and low costs for both the components used and the assembly process. Often, further requirements arise due to constraints such as limited space and restricted visibility.

[0003] These and potentially other requirements are particularly critical and difficult to meet in field operations, for example, during the installation, maintenance, and repair of electrical systems. Sometimes, due to space constraints, one-handed work is necessary.

[0004] German patent DE 29605034U 1 discloses a connector for electrical cables with multiple conductors, in particular for flat cables. The plugs and / or sockets of the connector are each arranged in a housing with a clamping device for the simultaneous insertion and subsequent simultaneous clamping of the electrical conductors. SUMMARY OF THE INVENTION

[0005] It turns out that known methods and devices, such as soldering, conductive gluing and crimping, often cannot meet the requirements or can only do so inadequately.

[0006] Against this background, the object of the present invention is to further develop the prior art with regard to connecting wires. Preferably, the situation is improved with regard to one or more of the problems mentioned above.

[0007] The technical problem is solved by the subject matter of the independent patent claims. The dependent claims, as well as the description and the drawings, define exemplary and advantageous embodiments.

[0008] According to one aspect, the technical problem is solved by an electrical connector for a wire with a wire end. Extending from the wire end are an uninsulated wire segment and an adjacent insulated wire segment. Together, the uninsulated and insulated wire segments form an insertion section. Thus, the wire has no insulation in the section extending to the wire end, which forms the uninsulated wire segment. This uninsulated wire segment is typically created by removing existing insulation or by stripping the wire. In the direction extending away from the wire end, the wire following the insulated wire segment of the insertion section can also be insulated, or the insulated wire can represent the end of an insulated portion of the wire. This insulated portion of the wire can, in principle, be of any length.

[0009] The electrical connector can be converted from an open configuration to a closed configuration. In a particular embodiment, the connector can also preferably be converted from the closed configuration to the open configuration without damage.

[0010] The connector comprises a body with a proximal and a distal side, as well as a top surface. The connector body also includes a channel for receiving the insertion segment. This channel extends along a channel axis within the connector body from a proximal end in a distal direction, with the proximal end opening into the proximal side of the connector body. The channel further comprises a top surface open towards the top surface of the connector body and a channel base. Channel depth is defined as the distance from the top surface of the connector body to the channel base, and channel width is defined as the distance between the channel faces that, together with the channel base, define the open channel. Neither the channel depth nor the channel width is necessarily constant along the length of the channel or along its axis.A direction transverse, particularly perpendicular, to the canal axis, extending between the open canal surface and the canal base, is called the depth direction, and a corresponding axis is called the depth axis. A direction transverse, particularly perpendicular, to both the canal axis and the depth axis is called the lateral direction, and a corresponding axis is called the lateral axis. The lateral axis extends between the canal lateral surfaces that connect the open canal surface to the canal base. A view along the depth axis from the canal surface to the canal base is called a top view, a view along the lateral axis is called a side view, and a view along the canal axis from proximal to distal is called a front view.

[0011] The connector body is formed from electrically insulating material, especially plastic.

[0012] The channel can have a cross-section perpendicular to the channel axis, for example, essentially a U-shaped cross-section, which is bounded by the channel side surfaces as the lateral boundaries or legs of the U, and by the channel base as the base of the U. In one embodiment, the channel side surfaces are essentially parallel to each other, or, in the case of varying channel width, parallel in sections. The channel base can be interrupted or have openings to a connector body underside. Likewise, the channel side surfaces can have interruptions or cutouts that connect the channel interior to lateral connector body sides, which can laterally bound the electrical connector and define its lateral outer surfaces.Parts of the connector body extending between the channel and the lateral connector body sides are called connector body side walls, and parts of the connector body extending between the channel base and the underside of the connector body are called connector body base.

[0013] The channel sides and the channel bed can meet at a sharp angle, for example, at a right angle. However, the transition area can also have a continuous transition with a curve.

[0014] In a further embodiment, the channel base is V-shaped in cross-section and then has a section on each side of the channel axis in the lateral direction, which meet obliquely and also obliquely meet the respective adjacent channel side surface. Such a design is advantageous to ensure reliable contact even if, after a prolonged period in the closed configuration, the metallization of the wire contact surface deteriorates due to flow of the connector body material or, due to this flow, works its way into the connector body material. In one variant, the channel can have a V-shaped or parabolic cross-section along part or all of its length, extending to the open channel top. In such a design, there is no explicit separation between the channel base and the channel side surfaces.

[0015] The electrical connector further comprises an electrical connection element. The electrical connection element has a wire contact surface arranged in the channel for contacting the uninsulated wire segment and a connection surface arranged on the outside of the connector body. The electrical connection element is formed by metallization, in particular partial metallization, of the connector body.

[0016] The electrical connector further comprises a cover element. The cover element has a clamping structure, wherein the clamping structure does not project into the channel in the open configuration of the electrical connector and projects into the channel from the open top of the channel in the closed configuration of the electrical connector. The cover element may have a base from which the clamping structure projects.

[0017] The clamping structure is designed to clamp the insertion section between the channel base and the clamping structure in the closed configuration, thus maintaining contact between the uninsulated wire segment and the wire contact surface. The clamping can be applied along the entire length of the uninsulated wire segment, or along a portion thereof, and / or in a number of sections along its length. Optionally, the clamping can also be applied along the entire length of the insulated wire segment, or along a portion thereof, and / or in a number of sections along its length.

[0018] In the closed configuration, the cover element in one embodiment completely or partially covers the channel or the open top of the channel.

[0019] It should be noted that directional terms such as "top", "bottom", "above", "below", "front", "back", "left", "right", etc., unless otherwise stated, generally serve only to describe the geometric relationships of the electrical connector and / or elements related to the electrical connector, but do not imply any specific position or orientation in the assembled state or a particular installation position. These can, in principle, be arbitrary.

[0020] According to another aspect, the technical problem is solved by a connector-wire arrangement. The connector-wire arrangement comprises an electrical connector according to one of the embodiments described above and / or below, and a wire with a wire end, wherein an uninsulated wire segment extending from the wire end and an insulated wire segment adjacent to the uninsulated end segment together form an insertion section, the insertion section being received in the channel.

[0021] According to another aspect, the technical problem is solved by a method for connecting a wire. The method comprises providing an electrical connector in an open configuration according to one of the embodiments described above and / or below. The method further comprises providing a wire with a wire end wherein an uninsulated wire segment extending from the wire end and an insulated wire segment adjacent to the uninsulated segment together form an insertion section. The method further comprises transferring the electrical connector from the open configuration to the closed configuration, whereby the insertion section is inserted into the channel and clamped between the clamping structure and the channel base, and the uninsulated wire segment is brought into contact with the wire contact surface.After the procedure has been carried out, the electrical connector and the wire together form a connector-wire assembly as previously described. When the electrical connector is transferred from the open to the closed configuration, deformation of the insertion section can occur due to contact with the cover element, in particular the clamping structure, and the connector body, in particular the channel base. The wire, or rather its insertion section, is typically provided in a substantially straight initial shape, and the deformation of the insertion section typically occurs in a plane in which the channel axis and a cover element axis lie, as described below, or in a plane perpendicular to the lateral direction.

[0022] Advantageous embodiments of the method are described below and illustrated in the figures. In particular, specific embodiments of the electrical connector also disclose corresponding embodiments of the method according to the invention.

[0023] A sophisticated electrical connector can be manufactured cost-effectively and in large quantities. At the same time, high reliability can be achieved in operation. Furthermore, by converting the electrical connector from the open to the closed configuration, a secure mechanical and electrical connection between the wire and the connector is established in a single step or movement.

[0024] The wire insertion and the closing of the connector, or its transition from the open to the closed configuration, can be performed manually, typically requiring no additional tools. This makes a sophisticated electrical connector particularly suitable for field use. Alternatively or optionally, however, full or partial automation can be implemented.

[0025] The electrical connector as a whole, or at least the connector body, can be manufactured together with the electrical connection element as an injection-molded interconnected device (MID) or be an MID component. In principle, the connector body and / or the cover element can also be manufactured using other methods, such as machining and / or additive manufacturing processes like 3D printing. Suitable materials include amorphous or semi-crystalline thermoplastics such as PC-ABS, PPA, LCP, or PEEK. Furthermore, thermosets, for example, phenolic resin-based or light-cured, and / or ceramics can be used.

[0026] Depending on the requirements and the material of the connector body, the metallization can have different structures and can be single- or multi-layered. A generally suitable layer structure, for example, is three-layered and has a layer sequence of copper (Cu) - nickel (Ni) - gold (Au).

[0027] Depending on the embodiment, the electrical connector, and in particular the connector body, can be designed for mounting on a printed circuit board (PCB). For this purpose, the contact surface for electrical contact can be designed accordingly, and a corresponding mechanical interface can be provided on the connector body. Furthermore, the electrical connector can be designed additionally or alternatively for mounting on an electrical / electronic device or assembly. The electrical connector, and in particular the connector body, can also be integral to an electrical / electronic device or assembly and form part of it. Thus, the electrical connector, and in particular the connector body itself, can be an integral part of a MID component or MID assembly.

[0028] When designed as a separate component, the connector, and in particular the connector body, can be realized as an elongated element whose longitudinal extent runs along the channel axis. The total length between the proximal and distal sides of the connector body is typically determined by the length of the channel between the proximal and distal ends, or is slightly longer than this length.

[0029] Viewed along the channel axis, the connector body can, for example, have a substantially square or rectangular cross-section. The channel typically runs symmetrically between the lateral sides of the connector body. The channel axis can also represent a connector body axis.

[0030] The connector body can have a substantially smooth underside, which may, for example, run parallel to the top surface. The underside of the connector body can be designed, for instance, for mounting on a printed circuit board. Optionally, the underside of the connector body can also carry the contact surface. In such a configuration, the connector can be designed for surface mounting as an SMD (Surface Mounted Device).

[0031] The canal is typically open longitudinally, i.e., along the canal axis, towards the proximal side of the connector body, while a distal end of the canal is closed or terminates within the connector body. However, the canal can also be open and thus continuous towards the distal side of the connector body.

[0032] In one embodiment, the lateral sides of the connector body can be parallel to each other and essentially smooth when viewed along the channel axis or connector body axis. This is the case, for example, for a square or rectangular cross-section as described above. Such a design allows for the arrangement of multiple connectors, with the connector body axes, and thus the channel axes of the individual connectors, being parallel to each other. Optionally, the lateral sides of the connector body can include alignment and / or coupling structures for mutual alignment and connection of multiple connectors or connector bodies. Such alignment and / or coupling structures can include concave and convex elements designed for mutual engagement, such as projecting lugs, pins, or bulges as convex elements and corresponding recesses, grooves, depressions, or blind holes as concave elements.Tongue and groove elements are also possible. Furthermore, such a coupling structure can include locking elements for mutual interlocking, such as snap-fit ​​elements. Additionally, several connector bodies and / or cover elements can be manufactured together in one piece, thus forming an electrical multi-connector. In such a configuration, the connector body sidewalls of the individual connectors of the multi-connector can be integrally formed together or merge seamlessly into one another.

[0033] The cover element, like the connector body, can have a proximal and a distal cover element side. The length of the cover element can correspond at least substantially to the length of the connector body, or the distance between the proximal and distal covers element sides can correspond to the distance between the proximal and distal connector body sides. Likewise, the lateral extent of the cover can substantially correspond to that of the connector body. In a top view, the connector body and cover element can be at least substantially congruent.

[0034] The clamping structure typically extends along a cover element axis, which in the closed configuration can run parallel to the channel axis or the connector body axis. The clamping structure can be formed by one or more convex elements such as pins, studs, lugs, and / or arc-shaped segments as described below, which can be arranged one behind the other and spaced apart from each other, or directly adjacent to each other along the cover element axis. In one embodiment, the clamping structure can be formed by a rib projecting from a cover element base, the height of which, or its distance from the cover element base surface, varies along the cover element axis.

[0035] In one embodiment, the connector body and the cover element are formed in one piece. In such an embodiment, the electrical connector can be realized as a single piece, in particular as a single injection-molded piece with partial metallization for the electrical connection element. Alternatively, the cover element can also be realized as a separate component.

[0036] In principle, the same materials and manufacturing processes are suitable for the cover element as for the connector body. The cover element, like the connector body, is typically made of an electrically insulating material.

[0037] In one embodiment, the connector body and the cover element are connected by means of a hinge, the hinge pivotally connecting the distal side of the connector body and a distal side of the cover element. In a one-piece design of the connector body and cover element, the hinge can be implemented, in particular, as a film or foil hinge. In an alternative embodiment, however, the hinge can also be designed in two parts, with each hinge part being part of the connector body or the cover element and being integrally formed or molded with it.

[0038] The hinge axis typically runs transversely to the channel or along the lateral direction. In this configuration, the connector body and the cover element are connected at their respective distal sides in the open configuration and open from there towards their opposite proximal sides, so that the cover element projects obliquely from the connector body. When transitioning to the closed configuration, the cover element pivots about the hinge axis relative to the connector body. In the closed configuration, the final state, a peripheral area of ​​the cover element, which completely or partially surrounds the clamping structure, can rest on the upper surface of the connector body.

[0039] In one embodiment, the electrical connector includes a locking device. The locking device comprises a locking structure on the connector body and a locking structure on the cover element. The locking structures on the connector body and the cover element are designed for the latching, and in particular releasable, locking of the connector body and the cover element by means of a positive engagement between the locking structures on the connector body and the cover element.

[0040] The locking structure on the connector body side and the locking structure on the cover element side can each be arranged in a proximal region of the connector body or cover element, respectively, and can each be integrally formed on the connector body or cover element. One of the two locking structures, in particular the locking structure on the cover element side, can be implemented by one or more convex structural elements, such as elastically springy hooks or lugs, pins, or latches. Correspondingly, the other locking structure, in particular the locking structure on the connector body side, can be formed by corresponding concave structural elements, such as recesses or openings, into which the convex structural elements engage to lock the components. The locking structure on the connector body side can, for example, be arranged by recesses in the opposing channel side surfaces.At least one of the locking structures, such as the locking structure on the cover element side, can be elastically resilient, particularly in the lateral direction. In one embodiment, the locking structure on the connector body side can be arranged on both sides of the channel axis or connector body axis, or have a portion on each side of the channel axis or connector body axis. Similarly, the locking structure on the cover element side can be arranged on both sides of the cover element axis, or have a portion on each side of the cover element axis.

[0041] The locking mechanism engages when the cover element reaches its end position during the transition from the open to the closed configuration. This ensures that the closed configuration is maintained, the clamping of the insertion section, particularly the uninsulated wire segment, is retained, and the uninsulated wire segment is kept in secure electrical contact with the wire contact surface. The locking mechanism also prevents the connector from opening unintentionally due to elastic forces exerted by the uninsulated wire segment, as described below.

[0042] Alternatively or in addition to a locking device of the electrical connector, the connector body and the cover element can also be held in the closed configuration by a separate device which is not itself part of the electrical connector, such as a clamping device.

[0043] In a design with strain relief as described below, the locking structure on the connector body side can, for example, connect distally to the strain relief structure on the connector body side. Similarly, the locking structure on the cover element side can connect distally to a strain relief structure on the cover element side.

[0044] In one embodiment, the electrical connector has a wire stop for axially positioning or fixing the insertion section of the wire relative to the electrical connector. The wire stop can form a stop for an end face of insulation on the insulated wire segment at the transition to the uninsulated wire segment, or be formed by such a stop. The wire stop has a wire passage with a width or extent in a direction transverse to the wire axis, or in a lateral direction, that corresponds to the diameter of the uninsulated wire segment, i.e., the wire without insulation, or advantageously is slightly larger but smaller than the diameter of the insulated wire segment.

[0045] In one embodiment, the wire stop is arranged on the cover element and can, in particular, be part of the cover element. The wire stop can be integral with a locking structure on the cover element side, or a locking structure on the cover element side can simultaneously serve as the wire stop. For this purpose, the locking structure on the cover element side can each have a hook or blade element on both sides of the cover element axis, as described above. The clear distance between the hook or latch elements is dimensioned such that the uninsulated wire segment fits between them, while the end face of the insulation abuts the hook or latch elements, in particular their proximal end faces. In further embodiments, however, the wire stop can also be implemented differently, for example, by appropriately spaced webs or pins on both sides of the cover element axis.Additionally or alternatively, an end cap as described below can serve as a wire stop.

[0046] According to the claim, the channel base and the clamping structure are designed to deform the uninsulated wire segment during the transition from the open to the closed configuration. For this purpose, the channel depth can vary along the channel axis, or the channel base can have a varying distance from the channel surface along the channel axis. This causes a deformation of the uninsulated wire segment corresponding to the channel base when transitioning from the open to the closed configuration. The deformation occurs in the direction of the channel depth or in a plane defined by the channel axis and the cover element axis, for example, with no or only minor or negligible lateral deformation. Optionally, lateral deformation can also occur to increase the contact area or improve contact reliability.Such a design is advantageous with regard to contact reliability and the larger contact area between wire and wire contact surface compared to a straight extension.

[0047] Depending on the wire's design and material properties, its deformation can be completely or primarily plastic, or partially elastic. Partially elastic deformation means that the wire, or rather the uninsulated wire segment, exhibits residual elastic stress in the closed configuration. This increases the contact pressure between the uninsulated wire segment and the wire contact surface. Furthermore, this residual elastic stress ensures that contact is maintained even if, after prolonged periods in the closed configuration, the metallization of the wire contact surface deteriorates due to material flow within the connector body.

[0048] In one embodiment, the channel base and the clamping structure are designed to form a number of arc-shaped sections along the channel axis in the uninsulated wire segment. For this purpose, the channel depth can be designed in arc-shaped sections along the channel axis. In a specific embodiment, the arc-shaped sections can be designed as circular arcs, for example, semicircular, or as parabolic arcs or elliptical shapes in a side view. In another embodiment, two or more such arc-shaped sections can be arranged one behind the other, with the arc-shaped sections either directly adjoining each other or, for example, being separated from each other by straight or curved sections.

[0049] In one embodiment, the connector body has a counter-clamping structure, wherein, in the closed configuration, the clamping structure and the counter-clamping structure interlock and, in particular, receive and clamp the uninsulated wire segment between them. The counter-clamping structure is formed by the channel base, the channel depth of which varies along the channel axis. During the closing of the connector, or during the transition from the open to the closed configuration, the uninsulated wire segment is deformed or bent according to the shape of the clamping structure and counter-clamping structure, or the channel base. In one embodiment, the clamping structure and the counter-clamping structure each comprise complementary arc-shaped segments as described above.

[0050] In one embodiment, the wire contact surface extends at least partially onto the channel base. The channel base is accordingly metallized. In such a configuration, the uninsulated wire segment, in the closed configuration, is securely pressed against the wire contact surface by the cover element or the clamping structure. This configuration is particularly advantageous in conjunction with a device as previously described, which, in the engaged or locked state, ensures the pressure between the uninsulated wire segment and the wire contact surface. In further embodiments, the wire contact surface can extend wholly or partially onto the channel's side surfaces.

[0051] In one embodiment, the wire contact surface comprises a plurality of contact surface segments, which are electrically connected to one another by a connecting conductor of the metallization. The contact surface segments can be arranged, for example, on arc-shaped segments, in particular arc-shaped segments of a counter-clamping structure as described above. The connecting conductor itself can be multi-part and connect adjacent contact surface segments or those arranged one behind the other along the channel axis. The connecting conductor can, in particular, run on the channel side surfaces and / or on the upper surface of the connector body, for example, on both sides of the channel axis or connector body axis.

[0052] In one embodiment, the electrical connector has a strain relief. The strain relief structure can be arranged, in particular, in a proximal area and is designed to clamp the insulated wire segment in the closed configuration. For this purpose, the connector body can have a strain relief structure on the connector body side and the cover element on the cover element side. The strain relief structures on the connector body side and on the cover element side are designed to accommodate and clamp the insulation of the insulated wire segment between them in the closed configuration. In one embodiment, the strain relief structures on the connector body side and on the cover element side are complementary to each other and interlock in the closed configuration, with the wire or...The insulated wire segment is deformed or bent accordingly during the transition from the open to the closed configuration. The strain relief structure on the connector body side and the cover element side can be designed in a generally known manner, for example, each in the form of a wave structure. In further embodiments, the clamping structure on the connector body side and the cover element side are not strictly complementary to each other, but are each formed, for example, by a roughening or a number of studs or similar features that engage with the insulation.

[0053] In one embodiment, the canal base terminates at a distal end in an end receptacle. The end receptacle is designed to accommodate an end section of the uninsulated wire segment extending from the wire end, the end receptacle being at an angle, in particular a right angle, to the canal axis.

[0054] The end receptacle can be formed by a recess, bore, or channel extending perpendicularly or obliquely from the canal base at the distal end towards the underside of the connector body. The end receptacle can be open or closed towards the underside of the connector body.

[0055] During the wire insertion and positioning process, the end section of the electrical connector is inserted into the end receptacle with the wire end first in the open configuration. When transitioning to the closed configuration, the wire, particularly the uninsulated wire segment, is pressed into the channel and bent at the transition between the channel base and the end receptacle according to the angle between the channel axis and the end receptacle, for example, at a right angle. This bending prevents the insertion section from being pulled out of the electrical connector in the closed configuration and thus serves as a pull-out protection device.

[0056] If the end receptacle is closed towards the underside of the connector body and, for example, designed as a blind hole, the base of the end receptacle can also serve as a wire stop. In this case, the wire is inserted into the end receptacle until the wire end abuts the base of the blind hole. The same effect can be achieved with an end receptacle that extends to the underside of the connector body by means of a shoulder or a shoulder.

[0057] In one embodiment, the metallization electrically connects the wire contact surface and the terminal surface through an opening in the connector body. In such a configuration, the metallization completely or partially covers one or more inner walls of the opening. The opening can extend from the channel base to the underside of the connector body. Alternatively or additionally, the portion of the metallization connecting the wire contact surface and the terminal surface can also extend externally or onto an outer surface of the connector body.

[0058] In one embodiment, the connector body has a connection structure, wherein the connection surface is at least partially arranged on the connection structure. The connection structure can be formed, in particular, by one or more convex elements, such as connecting pins or studs. Connecting pins or studs can, for example, be arranged on the otherwise essentially flat underside of the connector body and project from it. During assembly of the electrical connector, the connecting pins can be inserted into corresponding bores or recesses. Instead of or in addition to the underside of the connector body, the connection structure can also be arranged, for example, on one or both lateral sides of the connector body.

[0059] In one embodiment, positioning and connection structures can be provided in the form of convex or projecting positioning elements such as positioning pins, positioning studs, positioning lugs, positioning ridges, or positioning ribs. In another embodiment, a number of positioning elements are provided, which extend along or parallel to the connector body axis or channel axis and project from the underside of the connector body. During assembly, they can ensure a defined direction of the connector or channel axis. In a special embodiment, one or more positioning elements can simultaneously serve as a connection structure as described above.For both a connection structure and positioning elements as a whole, it is optional that these can also be formed wholly or partially by negative features, such as recesses and indentations, into which corresponding convex counter-elements, such as positioning pins, positioning ridges or positioning ribs or positioning pins, engage during assembly.

[0060] In one embodiment, the cover element has guide elements, wherein, in the closed configuration, the guide elements project into the connector body from the top of the connector body on both sides of the channel axis.

[0061] Guide elements can be arranged in pairs on both sides and symmetrically to the lid element axis, and a number of guide elements can be arranged one behind the other along the lid element axis, optionally spaced apart from each other. The clear distance, or lateral distance, between a pair of guide elements is dimensioned to correspond to the wire diameter or be slightly larger, allowing the wire to run between them with minimal play. The guide elements can be arranged, in particular along the lid element axis, in an area that corresponds to the uninsulated wire segment in the closed configuration, or can be designed to guide the uninsulated wire segment. The guide elements ensure that the wire, or its insertion section, is guided in a single plane during the transition from the open to the closed configuration.not breaking out laterally, i.e., perpendicular to the channel axis.

[0062] The guide elements, as previously described for the clamping structure, can project from the base of the cover element and be shaped, for example, as pins, ribs, or tongues. The guide elements can be arranged in pairs on both sides of the clamping structure in a lateral direction.

[0063] The connector body can have corresponding concave guide element receptacles, such as recesses and / or widenings or setbacks of the channel side surfaces, into which the guide elements engage when transitioning from the open to the closed configuration.

[0064] Furthermore, the guide elements can project further from the base of the cover element than the clamping structure. In this way, during the transition from the open to the closed configuration, they are the first to engage with their guide element receptacles, thus ensuring a defined movement of the cover element and preventing jamming, tilting, or canting. Depending on the design, this function can be provided in addition to or as an alternative to guiding the wire or its insertion section.

[0065] In one embodiment, elements of a grid structure as described above can serve as guide elements and guide element receptacles.

[0066] In one embodiment, the electrical connector has a stripping device, in particular a stripping blade. A stripping blade can be integrally formed with the cover element or form part of the cover element. The stripping blade can be implemented, for example, by a burr or a suitably shaped sharp edge of the locking structure on the cover element side, as described above. Such a stripping device serves the typically manual stripping of the wire or the removal of the insulation in the area of ​​the stripped wire segment. In principle, however, a stripping device can also be integrally formed with the connector body or form part of the connector body. Integrating a stripping device into the electrical connector has the advantage that no separate stripping tool needs to be provided or carried, which is particularly advantageous in field use. BRIEF FIGURE DESCRIPTION

[0067] They show Fig. 1 a perspective view of an exemplary electrical connector according to the disclosure in an open configuration together with a wire in an initial state in longitudinal section; Fig. 2 a Figure 1 Corresponding representation with uncut electrical connector; Fig. 3 a to Figure 2 corresponding distal detail view; Fig. 4 the electrical connector with wire according to Figure 1 in an intermediate state during the transition from the open configuration to the closed configuration; Fig. 5 the electrical connector with wire according to Figure 1 in a final state after reaching the closed configuration; Fig. 6 the electrical connector and wire according to Figure 1 in the closed configuration in perspective view as an exploded view; Fig. 7 a to Figure 6 corresponding side view. EXAMPLES OF EXECUTION

[0068] Exemplary embodiments of the invention are described in more detail below with reference to the figures. For the sake of clarity, not all features in all figures are provided with reference numerals. Likewise, identical or corresponding features that occur multiple times are not necessarily each individually provided with reference numerals.

[0069] A proximal and a distal direction are designated P and D, respectively. Additionally, a Cartesian coordinate system with coordinate axes x, y, z is used. ( Figure 2 ) provided for, with a direction from proximal to distal corresponding, for example, to the positive x-direction. A hinge axis is designated SA. ( Figure 1 ),where their direction corresponds, for example, to the direction of the z-axis or is parallel to it and simultaneously defines the lateral direction. A channel axis is denoted by KA, a cover element axis by GA, and a wire axis by DA (each). Figure 2 ). In the representation shown, the y-axis of the coordinate system also denotes the depth direction.

[0070] The construction of an exemplary electrical connector 1 according to the disclosure will be described below, in particular with reference to the Figure 1 , 2The diagram describes a section of wire 2 with an insertion section 21. The elongated connector body 11 extends from a proximal connector body side 11P in a distal direction to a distal connector body side 11D. The electrical connector 1 is exemplary in its mirror symmetry, with a channel axis KA corresponding to the connector body axis (not shown separately) running in the mirror plane, which is perpendicular to the lateral direction. Furthermore, the mirror plane runs through the cover element axis GA of a cover element 12.

[0071] In a side view, the connector body 11 has an essentially rectangular shape. A front view along the channel axis KA is also essentially rectangular or square, resulting in an overall elongated cuboid shape. Other configurations are also possible.

[0072] The connector body 11 has a substantially smooth or flat underside 11u and a parallel upper side 11o, as well as parallel lateral sides 11b. In the example shown, the lateral sides 11b, or their outer surfaces, are also smooth or flat, so that, if required, a plurality of electrical connectors 1, or connector bodies 11, can be arranged side by side.

[0073] A channel 111 extends from the connector body's upper surface 11o in the direction of depth towards the connector body's lower surface 11u into the connector body 11. The channel has an open upper surface 111o, which serves for inserting the wire 2 or its insertion section 21, as described below. The channel 111 is bounded laterally by two channel side surfaces 111b. The channel 111 extends along a channel axis KA, which in the example shown coincides with the connector body axis. The channel also has a channel base 111a, which is arranged between and connects the channel side surfaces 111b. A perpendicular distance from the open upper surface 111o to the channel base 111a indicates a channel depth, which in the example shown varies along the channel axis KA, as described below.A lateral distance perpendicular to the channel axis KA corresponds to the channel width, which in the example shown also varies along the channel axis KA. Furthermore, the channel base 111a in the example shown is not continuous along the channel axis KA, but has interruptions or openings to the underside of the connector body 11u. The channel side surfaces 111b together with the channel base 111a form an essentially U-shaped channel cross-section.

[0074] At a distal end of the canal, the canal base 111a opens into a blind hole 118 extending towards the underside of the connector body 11u, serving as an end receptacle and wire stop. The blind hole 118 extends from the canal base 111a perpendicularly to the canal axis KA towards the underside of the connector body 11u. Alternatively, a through hole can be provided instead of a blind hole.

[0075] In the illustrated embodiment, a cover element 12 of the electrical connector 1 has a cover element base 126 in the form of a flat rectangular disc or cover. A top view of the cover element 12 corresponds essentially to the top view of the connector body 11. The cover element 12 extends from a proximal cover element side 12P along a cover element axis GA to a distal cover element side 12D.

[0076] In the illustrated embodiment, the connector body 11 and the cover element 12 are connected at their respective distal sides 11D, 12D by a hinge 14, the hinge axis SA extending laterally. The cover element 12 can be pivoted about the hinge axis relative to the connector body 11.

[0077] The connector body 11 and the cover element 12 are shown as two separate components, each typically an injection-molded plastic part. One hinge part of the hinge 14 is integrally formed with the connector body 11, and the other hinge part with the cover element 12. However, the connector body 11 and the cover element 12 can also be manufactured as a single piece with the hinge 14. In this case, the hinge 14 is implemented, for example, as a film or foil hinge. In an alternative embodiment, the connector body 11 and the cover element 12 can also be separate parts without a hinge, with the cover element being placed, for example, onto the connector body to transition from the open to the closed configuration.

[0078] The cover element has a clamping structure with, for example, three arc-shaped segments 122a, which are arranged one behind the other along the cover element axis GA and together form a web 122. The web width transverse to the channel axis or in the lateral direction is slightly narrower than the channel width, so that the web 122 can extend into the channel 111 from the open channel top 111o. The connector body 11 has a counter-clamping structure along the connector body axis or channel axis KA, which comprises a corresponding complementary element in the form of an arc-shaped segment 112 for each arc-shaped segment 122a of the clamping structure. The arc-shaped segments 112 each form part of the channel base 111a.

[0079] In the embodiment shown, the arc-shaped segments 112 meet the channel side surfaces 111b at an oblique angle, so that the channel bottom 111a has a V-shaped cross-section in the area of ​​the arc-shaped segments 112.

[0080] Along the lid element axis GA between the arc-shaped segments 1 22a, or at the boundary of successive arc-shaped segments 122a, guide elements in the form of guide tongues 125 with an exemplary rectangular cross-section are arranged in pairs opposite each other with respect to the lid element axis GA. The guide tongues 125, like the clamping structure or the web 122 forming the arc-shaped segments 1 22a, project perpendicularly from the lid element base 126. The guide tongues 125 project further than the arc-shaped segments 122a or project beyond them.

[0081] To accommodate the guide tongues 125, the connector body 11 has a corresponding guide element receptacle or guide tongue receptacle 115 for each guide tongue 125. In this embodiment, the guide tongue receptacles 115 are realized by continuous receiving recesses on the inner surfaces of the connector body side walls 11a or by lateral widenings of the channel 111, extending in the depth direction or between the upper surface 11a and the lower surface 11u of the connector body. This also interrupts the channel base 111a along the channel axis KA between the arc-shaped segments 112 of the counter-clamping structure.

[0082] The electrical connector 1 further comprises a locking device. The locking device includes a locking structure on the cover element side, which is realized by spring-loaded latches 124 extending laterally, i.e., transversely to the cover element axis GA. The spring-loaded latches 124 project from the cover element base 126 in a similar manner to the guide tongues 125 and, like them, are arranged in pairs on both sides of the cover element axis GA. The latch surfaces of the spring-loaded blades 124 are directed outwards, i.e., away from the cover element axis GA. The mutually facing inner surfaces of the spring-loaded latches 124 have a clear distance from each other such that they can accommodate the uninsulated wire or the uninsulated wire segment 211 between them, but not the insulated wire segment 212, so that they can simultaneously serve as a wire stop.

[0083] To accommodate the spring-loaded latches 124, the connector body 11 has an upper latch receptacle 114o and a lower latch receptacle 114u for each of the two spring-loaded latches 124. The upper latch receptacles 114o are open towards the upper surface 11o of the connector body, and the lower latch receptacles 114u are open towards the underside 11u of the connector body, so that the channel base 111a is interrupted in the area of ​​the latch receptacles 114o and 114u. The upper and lower latch receptacles 114o and 114u are each formed by a recess on the inner sides of the connector body side walls 11a, with the upper latch receptacle 114o and the lower latch receptacle 114u not being continuous from each other. The upper and lower latch receptacles 114o, 114u together form a locking structure on the connector body.If the electrical connector 1 is to be designed such that it can be converted from the closed to the open configuration, the spring-loaded latches 124 can be elastically deformed laterally inwards from below, for example by a tool such as appropriately designed pliers, so that they can be released from the lower latch receptacles 114u. Furthermore, corresponding openings in the connector body side walls 11a can optionally be provided for this purpose, either alternatively or additionally.

[0084] Furthermore, the connector body 11 features a strain relief with a connector body-side strain relief structure 113 and a complementary cover element-side strain relief structure 123, which interlock in the closed configuration. The connector body-side strain relief structure 113 forms a proximal part of the channel base 111a. The spring-loaded latches are arranged distally adjacent to the cover element-side strain relief structure 123, and the latch receptacles 114o, 114u are arranged distally D adjacent to the connector body-side strain relief structure 113.

[0085] A partial metallization 13 is applied to the connector body 11. The metallization 13 covers the channel base 111a, particularly in the area of ​​the bottom-shaped segments 112 of the counter-clamping structure, thereby forming a wire contact surface 131. The individual segments or sections of the wire contact surface 131 (corresponding to the arc-shaped segments 112 of the counter-clamping structure) are connected via a connecting conductor 133, which also forms part of the partial metallization 13. In this embodiment, the connecting conductor 133 is guided across the channel side surfaces 111b and the upper surface 11o of the connector body.

[0086] Projecting from the underside 11u of the connector body, the connector body 11 further comprises a number of positioning pins 117, for example three, arranged along the axis of the connector body. In the illustrated embodiment, one of the positioning pins 117, for example the middle one, also serves as a connecting pin 116. For this purpose, the metallization 13 extends over the inner wall of an adjacent guide tongue receptacle 115 onto the outer surface of the connecting pin 116, whereby the metallization 113 forms a contact surface 132 on the connecting pin 116. When the positioning pins 117 and, in particular, the connecting pin 116 are inserted into corresponding bores, e.g., in a printed circuit board or an assembly, the contact surface 132 can be electrically connected, e.g., by soldering or clamping the connecting pin 116.

[0087] The following refers to the additional points below. Figures 3, 4 , 5, 6, 7A claimed method for connecting the wire 2 is described. The insertion section 21 of the wire 2 has an insulated wire segment 112 and a subsequent uninsulated wire segment 211, wherein the uninsulated wire segment 211 terminates with a wire end 22 as its end face. Although not strictly necessary, the wire 2 is assumed here to have a circular cross-section or rotational symmetry about the wire axis DA.

[0088] As in the Figure 1 , 2 , 3 As shown, the wire 2 is positioned or provided such that its wire axis DA is aligned with the axis of the blind hole 118 and its end section 23 is inserted into the blind hole 118 in the insertion direction E with the wire end 22 leading, until the wire end 22 touches its base which serves as a wire stop.

[0089] The electrical connector 1 is in the open configuration and the wire 2 or its insertion section 21 extends, after the insertion of the end section 23 into the blind hole 118, essentially perpendicular to the top of the connector body 110.

[0090] Furthermore, the wire 2 and the cover element 12 are positioned relative to each other such that the uninsulated wire segment 211 lies between the spring-loaded latches 124 and guide tongues 125 opposite each other along the cover element axis GA.

[0091] The insulation in the uninsulated wire segment 211 can be removed beforehand using a separate tool or a stripping device integrated or molded into the electrical connector, as described above. Alternatively, the wire can be supplied pre-assembled accordingly.

[0092] Subsequently, the electrical connector 1 is transferred from the open configuration to the closed configuration, which is achieved by a pivoting movement of the cover element 12 about the hinge axis SA with a pivoting direction S towards the connector body 11. ( Figure 4 ). The wire end 22 is held or fixed in the blind hole 118 and the wire is bent over by the cover element 12 at the transition between the blind hole 118 and the channel bottom 111a.

[0093] As the pivoting movement continues, the cover element 12 finally comes to rest on the connector body 11 or its connector body top 11o. ( Figure 5 ). In this process, the uninsulated wire segment 211 is deformed during the pivoting movement between the arc-shaped segments 122a of the clamping structure and the arc-shaped segments 112 of the counter-clamping structure, resulting in a wave-like pattern in the area of ​​the uninsulated wire segment 211.( Figures 6, 7 ).

[0094] Also during the pivoting movement, the guide tongues 125 from the upper surface 11o of the connector body dip into the guide tongue receptacles 115, and in a final phase shortly before reaching the closed configuration, the spring-loaded pawls 124 first engage in the respective upper pawl receptacles 114o. An edge at the transition from the upper pawl receptacles 114o to the part of the channel side surface 111b located between the upper pawl receptacles 114o and the lower pawl receptacles 114u elastically forces the spring-loaded pawls 124 laterally inwards, i.e., towards the cover element axis GA. When transitioning into the respective lower latch receptacles 114u, the spring-loaded latches 124 spring back outwards in a lateral direction, with each spring-loaded latch 124 engaging in the corresponding lower latch receptacle 114u, so that the cover element 12 is locked with the connector body 11.The locking or snapping action is preferably accompanied by an audible acoustic feedback, in particular a click, which marks the final state or the achievement of the closed configuration.

[0095] In this state, the insulated wire segment 212 is also received and clamped between the connector body-side strain relief structure 113 and the cover element-side strain relief structure 123, and the insertion section 21 of the wire 2 is fully inserted into the channel 111. As in Figure 5 As can be seen, wire 2 protrudes from channel 111 on the proximal connector body side 11P.

[0096] Due to the locking of connector body 11 and cover element 12, the uninsulated wire segment 211 is firmly clamped between the arc-shaped segments 122a of the clamping structure and the arc-shaped segments 112 of the counter-clamping structure or the channel base 111a, thus ensuring a secure pressure of the uninsulated wire segment 211 with the wire contact surface 131.

[0097] In the closed configuration of the electrical connector 1, the proximal end faces 124P of the spring-loaded latches 124 also serve as wire stops. If a through hole is provided instead of the blind hole 118, the end faces 124P also serve as wire stops for the initial positioning of the wire. If the blind hole 118 is present, a wire stop provided by the spring-loaded latches 124 or their proximal end faces can optionally be omitted.

[0098] The entire process can be performed by a single user with one hand and is largely error-free. A particular advantage is that the transition of the electrical connector from the open to the closed configuration, and thus the connection of wire 2, is accomplished with a single movement, namely the pivoting movement of the cover element 12. REFERENCE MARK

[0099] 1 Electrical connector 11 Connector body 11P Proximal connector body side 11D Distal connector body side 11a Connector body side wall 11b Lateral connector body side 11o Connector body top 11u Connector body bottom 111 Channel 111a Channel base 111P Proximal channel end 111a Channel base 111b Channel side surface 111o Open channel top 112 Arc-shaped segment (counter-clamp structure) 113 Connector body side strain relief structure 114o Upper latch receptacle 114u Lower latch receptacle 115 Guide tongue receptacle 116 Connecting pin 117 Positioning pin 118 Blind hole 12 Cover element 12P Proximal cover element side 12D Distal cover element side 122 Web 122a Arc-shaped segment (Clamping structure) 123 Cover element-side strain relief structure 124 Spring-loaded latch (cover element-side locking structure) 124 Proximal end face (spring-loaded latch) 125 Guide tongue 126 Cover element base 13 Metallization,electrical connection element 131 wire contact surface 132 connection surface 133 connecting conductor 14 hinge 2 wire 21 insertion section 211 uninsulated wire segment 212 insulated wire segment 22 wire end 23 end section E insertion direction D A wire axis G A cover element axis K A channel axis S A hinge axis (transverse axis) P proximal direction D distal direction S pivot direction x, y, z Coordinate axes,

Claims

1. An electrical connector (1) for a wire (2) having a wire end (22), wherein an uninsulated wire segment (211) extending from the wire end (22) and an insulated wire segment (212) adjacent to the uninsulated wire segment (211) together form an insertion section (21), wherein the electrical connector (1) is convertible from an open configuration to a closed configuration, wherein the electrical connector (1) comprises: a) a connector body (11) with a proximal (11P) and a distal (11D) connector body side and a connector body top (11o), - wherein the connector body (11) has a channel (111) for receiving the insertion section (21), - wherein the channel (111) extends in the connector body (11) along a channel axis (KA) from a proximal channel end in a distal direction (D), wherein the proximal channel end (111P) opens into the proximal connector body side, wherein the channel (111) has a channel top (111o) open toward the connector body top (11o) and a channel base (111a), - wherein the connector body (11) is formed from electrically insulating material; b) an electrical connection element, wherein the electrical connection element has a wire contact surface (131) arranged in the channel (111) for contacting the uninsulated wire segment (211) and a connection surface (132) arranged on the outside of the connector body (11); c) a cover element (12), wherein the cover element (12) has a clamping structure, wherein the clamping structure is adapted, in the closed configuration, to clamp the insertion section (12) between the channel base (111a) and the clamping structure and to hold the uninsulated wire segment (211) in contact with the wire contact surface (131), characterized in that the electrical connection element is formed by metallization, in particular partial metallization (13), of the connector body (11), the clamping structure does not protrude into the channel (111) in the open configuration and protrudes into the channel (111) from the open channel top (111o) in the closed configuration, and the channel base (111a) and the clamping structure are designed to deform the uninsulated wire segment (211) during the transition from the open configuration to the closed configuration.

2. Electrical connector (1) according to claim 1, wherein the connector body (11) and the cover element (12) are integrally molded.

3. Electrical connector (1) according to one of the preceding claims, wherein the connector body (11) and the cover element (12) are connected by means of a hinge (14), wherein the hinge (14) pivotally connects the distal connector body side (11D) and a distal cover element side (12D) and has a hinge axis (SA) oriented transversely to the channel (111).

4. Electrical connector (1) according to one of the preceding claims, wherein the electrical connector comprises a latching device, wherein the latching device comprises a connector body-side latching structure arranged on the connector body (11) and a cover element-side latching structure arranged on the cover element (12), wherein the connector body-side and cover element-side latching structures comprise latching elements for latching, in particular releasable latching, of the connector body (11) and the cover element (12) by form-fit engagement of the connector body-side and cover element-side latching structures.

5. Electrical connector (1) according to one of the preceding claims, wherein the electrical connector (1) has a wire stop for axially positioning the insertion section relative to the electrical connector.

6. Electrical connector (1) according to one of the preceding claims, wherein the channel base (111a) and the clamping structure are designed to form a number of arcuate sections in the uninsulated wire segment (211) along the channel axis.

7. Electrical connector (1) according to one of the preceding claims, wherein the wire contact surface (131) extends at least partially on the channel base (111a).

8. Electrical connector (1) according to one of the preceding claims, wherein the wire contact surface (131) comprises a plurality of contact surface segments which are electrically connected to each other by a connecting conductor (133) of the metallization (13).

9. Electrical connector (1) according to one of the preceding claims, wherein the electrical connector has a strain relief.

10. Electrical connector (1) according to one of the preceding claims, wherein the channel base (11 1a) at a distal channel end extends into an end receptacle, wherein the end receptacle is designed to receive an end portion (23) of the uninsulated wire segment (211) extending from the wire end, wherein the end receptacle extends at an angle, in particular a right angle, to the channel axis.

11. Electrical connector (1) according to one of the preceding claims, wherein metallization (13) electrically connects the wire contact surface (131) and the connection surface (132)through one or more openings in the connector body (11).

12. Electrical connector (1) according to one of the preceding claims, wherein the connector body (11) has a connection structure, in particular at least one protruding connection pin (116), wherein the connection surface (132) is arranged at least partially on the connection structure.

13. Electrical connector (1) according to one of the preceding claims, wherein the cover element (12) has guide elements, wherein in the closed configuration the guide elements protrude into the connector body (11) from the connector body top (11o) on both sides of the channel axis (KA).

14. Connector-wire arrangement comprising an electrical connector (1) according to one of the preceding claims and a wire (2) with a wire end (22), wherein an uninsulated wire segment (211) extending from the wire end (22) and an insulated wire segment (212) adjacent to the uninsulated wire segment (211) together form an insertion section (12), wherein the insertion section (12) is received in the channel (111).

15. Method for connecting a wire, the method comprising: - providing an electrical connector according to one of claims 1 to 13 in an open configuration and a wire (2) with a wire end (22), wherein an uninsulated wire segment (211) extending from the wire end (22) and an insulated wire segment (212) adjacent to the uninsulated wire segment (211) together form an insertion section (12); - transitioning the electrical connector (1) from the open configuration to the closed configuration, whereby the insertion section (12) is inserted into the channel and clamped between the clamping structure and the channel base, and the uninsulated wire segment (211) is deformed and brought into contact with the wire contact surface (131).