ELECTRICAL CONNECTOR, CONTACT INSERT AND METHOD FOR MANUFACTURING AN ELECTRICAL CONNECTOR

Description

[0001] The invention relates to an electrical connector with a locking unit and a contact insert at least partially surrounded by the locking unit. The invention further relates to a contact insert for an electrical connector.

[0002] Furthermore, the invention relates to a method for manufacturing an electrical connector.

[0003] Electrical connectors of the type in question are known from practice and are used, for example, in SPE-specific (Single Pair Ethernet) interfaces as well as in various screw connections, for example M8 or M12, with K-coding or L-coding, in particular connected to a mating connector.

[0004] For applications in automation technology, the amount of data to be transmitted by such a connector is relatively small; rather, the key factors are low price, small footprint, and ease of installation. The aforementioned criteria are not met, or only partially met, by known electrical connectors.

[0005] US 2011 / 0003507 A1 discloses a connector comprising a connector housing, an inner housing, and a connecting housing. DE 20 2016 102 392 U1 discloses a connector housing comprising a locking unit with a two-part contact insert. This document discloses the preamble of claim 1. .

[0006] The present invention therefore aims to design and further develop an electrical connector of the type mentioned above in such a way that an electrical connection requiring minimal space and cost-effective manufacturing can be achieved using simple design means. Furthermore, a method for manufacturing an electrical connector will be described.

[0007] According to the invention, the foregoing problem is solved by the features of claim 1. According to this claim, an electrical connector is formed with a locking unit and a contact insert at least partially surrounded by the locking unit, wherein at least one contact is arranged in and / or on the contact insert, wherein the contact insert is formed in two parts from a contact body and a contact sleeve connected to the contact body, wherein the contact body and the contact sleeve can be inserted into the locking unit on the connection side and plug-in side, characterized in that at least one projecting retaining element is formed on an outer side of the contact in order to realize a positive and / or force-fit connection between the individual components of the contact insert, namely the contact body and the contact sleeve, and the contact, and that the two parts of the contact insert are connected via the contacts.so that the locking unit is captive and fixed between a stop of the contact body and a stop of the contact sleeve,

[0008] With regard to the method, the problem is solved by the features of dependent claim 14. Thus, a method for manufacturing an electrical connector according to any one of claims 1 to 13 is claimed, comprising the following process steps: Providing a contact sleeve, in particular inserting the contact sleeve into an assembly tool, sliding a locking unit onto the contact sleeve, in particular up to a stop of the contact sleeve, inserting a contact body into the locking unit up to the contact sleeve, in particular inserting a probe area of ​​the contact body into a receiving area of ​​the contact sleeve, inserting at least one contact into the contact body.

[0009] In accordance with the invention, it has first been recognized that the underlying problem can be solved in a surprisingly simple manner by designing the contact insert in multiple parts. In contrast to a one-piece contact insert, there is thus no problem of having to press it through an opening in the locking unit, which regularly damages the necessary undercuts. Nor is there the problem of having to compress the circumferential stop of the plug-side contact insert excessively, which could damage any coding located there. Rather, in accordance with the invention, it is possible for the contact body and the contact sleeve to be inserted into the locking unit on both the connection and plug-side sides and connected to each other there, directly or indirectly, for example, by a form-fit and / or force-fit connection. This results in an extremely compact and easy-to-manufacture electrical connector.Furthermore, the contact insert can be modular, so that, depending on the desired connection type, only the connection-type-specific contact body needs to be selected. This allows for the easy implementation of various connection types, such as crimping, soldering, screw terminals, or cage clamp connections. It is also conceivable that the plug-side contact sleeve could be used universally. The contact itself could be, for example, a contact pin or a socket contact.

[0010] Advantageously, the contact body can have a probe area that can be inserted into a receiving area of ​​the contact sleeve. Alternatively, the contact sleeve can have a probe area that can be inserted into a receiving area of ​​the contact body. This allows for a particularly good connection between the contact body and the contact sleeve. A further advantage is that the material thickness of both the probe area and the receiving area can be optimized with regard to criteria such as compliance with contact forces, dielectric strength (due to thicker walls), UL requirements, and manufacturability (e.g., dimensional accuracy, minimizing warpage of plastic parts, injection molding of thin walls, etc.). Thus, the manufacturing and electrical / mechanical product requirements of the electrical connector can be met overall.In other words, it is conceivable that the contact body and contact insert can be at least partially slid into one another.

[0011] Advantageously, the contact body can be positively and / or force-fit connected to the contact sleeve. Alternatively or additionally, the contact can be positively and / or force-fit connected to the contact body and / or to the contact sleeve. According to a particularly preferred embodiment, the connection between the contact body and the contact sleeve is made by the contact that is integrated into the contact body. The contact can either be exclusively in contact with the contact body, e.g., positively and / or force-fit, pressing the contact body or the probe area outwards against the contact sleeve or the receiving area, or it can also be in contact with the contact sleeve, e.g., positively and / or force-fit.

[0012] According to a further advantageous embodiment, it is conceivable that at least one projecting retaining element, for example a retaining claw, is formed on an inner surface of the contact sleeve and / or on an outer surface of the contact body to create a positive and / or non-positive connection between the contact sleeve and the contact body. Alternatively or additionally, at least one projecting retaining element, for example a retaining claw, could be formed on an outer surface of the contact and / or on an inner surface of the contact body or the contact sleeve to create a positive and / or non-positive connection between the contact body or contact sleeve and the contact. If the contact is also in contact with the contact sleeve, corresponding retaining elements could alternatively or additionally be formed on the contact and / or the contact sleeve. Thus, the formation of detent elements on the contact insert can be omitted.This has the advantage that, when manufacturing the parts from plastic, the tools for producing the contact body and contact sleeve can be designed more simply and cost-effectively. Instead of a slide tool, a so-called open-close tool can be designed, which leads to inexpensive products, especially with multi-tools. Furthermore, it is advantageous that no detent elements are required to connect the contact body and contact sleeve and / or the contact insert and locking unit, making the actual assembly of the contact insert particularly easy, especially with regard to possible automation solutions, and resulting in a simple and compact overall design. Another advantage of the connection between the contact body and contact sleeve via the contact or...The advantage of this contact system is that the contact (retaining element) and contact sleeve only need to be adjusted once, without necessarily changing the entire electrical connector. The contact body can be structurally modified depending on the desired connection type without requiring any further revisions.

[0013] The contact insert can be advantageously connected to the locking unit by a positive-locking and / or force-locking connection. In particular, a stop is formed on the contact body, which engages the locking unit to create a positive-locking connection. Alternatively or additionally, the contact body can be connected to the locking unit via a fastening element, for example, a screw.

[0014] In a particularly preferred manner, a stop is formed on the contact sleeve with which the contact sleeve engages the locking unit.

[0015] Thus, a positioning aid and, if necessary, a positive-locking connection are created using simple means.

[0016] Furthermore, it is conceivable that the contact is connected to the contact body and / or to the locking unit via a fastening element, for example a screw.

[0017] In a further advantageous embodiment, the locking unit can comprise a union nut and a threaded ring, wherein the union nut is connected to the threaded ring via a grounding ring or a shielding ring. Furthermore, a stop could be formed on the grounding ring or shielding ring and on the union nut to achieve a positive-locking connection.

[0018] Advantageously, a recess can be formed on both the threaded ring and the grounding ring or shielding ring. A retaining ring can engage in these recesses to connect the threaded ring to the grounding ring or shielding ring. Alternatively or additionally, at least one snap element can be formed on the grounding ring or shielding ring, which engages behind a projection on the threaded ring.

[0019] Furthermore, it should be noted that the features of the method according to the invention discussed above can also have a device-like embodiment. A combination of these features with the features relating to the electrical connector is not only possible, but advantageous.

[0020] There are now various ways to advantageously elaborate and further develop the teaching of the present invention. For this purpose, reference is made, on the one hand, to the claims subordinate to claim 1 and, on the other hand, to the following explanation of preferred embodiments of the invention with reference to the drawings, on the basis of which the method according to the invention is also explained. In conjunction with the explanation of the preferred embodiments of the invention with reference to the drawings, generally preferred embodiments and further developments of the teaching are also explained. The drawings show Fig. 1 shows a schematic, cutaway view of an embodiment of a locking unit of an electrical connector according to the invention. Fig. 2 shows a schematic, cutaway view of an embodiment of an electrical connector according to the invention with the locking unit according to the invention. Fig. 1 Fig. 3 shows a further embodiment of a locking unit of an electrical connector according to the invention in a schematic, sectional view; Fig. 4 shows an embodiment of an electrical connector with the locking unit according to the invention in a schematic, sectional view. Fig. 3 Fig. 5 shows a schematic, cutaway view of a further embodiment of an electrical connector according to the invention with the locking unit according to Fig. 3 , Fig. 6 in a schematic, perspective view an embodiment of an electrical connector according to the invention with a housing, and Fig. 7 in a schematic, perspective view another embodiment of an electrical connector according to the invention with a housing.

[0021] Fig. 1 Figure 1 shows a schematic, cutaway view of an embodiment of a locking unit 1 with a PE connection of an electrical connector according to the invention. This pre-assembled unit comprises a grounding ring 2, a union nut 3, and a threaded ring 4.

[0022] The threaded ring 4 and the grounding ring 2 each have a recess 5, 6 or a groove, respectively, into which a retaining ring 7 engages and connects these components. Other designs for connecting the threaded ring 4 and the grounding ring 2 are also conceivable.

[0023] For pre-assembly of this component, the union nut 3 can be slid onto the grounding ring 2. A wave spring washer 8 can then be inserted, and the threaded ring 4 pressed onto the grounding ring 2. The retaining ring 7 connects these two components. The interposed wave spring washer 8 ensures permanent electrical contact between the union nut 3 and the threaded ring 4, thus providing EMC shielding.

[0024] According to Fig. 2 The connection between grounding ring 2 and contact 9 can be designed as a screw terminal contact and realized by means of a screw 10. This screw 10 can be tightened using a screwdriver, which could be inserted through an optional opening in the union nut 3.

[0025] Thus, the components of the locking unit 1 can also be mounted directly onto the contact insert 11. When the user assembles the electrical connector, the exposed wire is inserted into the contact 9 and secured with an additional screw.

[0026] Furthermore, for assembly, the retaining ring 7 can be pulled onto the grounding ring 2. Then, the O-ring 24 can be pulled onto the grounding ring 2 and the O-ring 24' inserted into the grounding ring 2. The contact body 12 is inserted into the grounding ring 2, and then the contact 9 is inserted and secured to the grounding ring 2 with a screw 10. Next, the union nut 3 can be fitted and the threaded ring 4 pressed onto the retaining ring 7. In the next step, the contact sleeve 13 can be inserted and the remaining contacts 9 are pressed in, so that the connection-side and plug-side parts of the contact insert 11 are connected. Finally, the screws 21 for clamping the stranded wire can be tightened.

[0027] In Fig. 2 It is clearly evident that the contact insert 11 is formed from a contact body 12 and a contact sleeve 13. The contact body 12 has a probe area 14, which is inserted into a receiving area 15 of the contact sleeve 13. The contact body 12 and the contact sleeve 13 are connected to each other by the retaining elements 16 of the contacts 9, which in this embodiment are formed as circumferential retaining claws. Furthermore, the contact body 12 and the contact sleeve 13 each have a stop 17, 18.

[0028] Fig. 3 Figure 1 shows another embodiment of a locking unit 1, which does not have a PE connection. This pre-assembled unit comprises the grounding ring 2, the union nut 3, and the threaded ring 4.

[0029] To mount the locking unit 1, the union nut 3 is pushed onto the shield ring 19. Then the threaded ring 4 is pressed onto the shield ring 19, which in turn has several flexible snap elements 20.

[0030] The threaded ring 4 cannot loosen once the contact insert 11 is fully assembled because the inserted contact insert 11 blocks the snap elements 20 of the shield ring 19. The electrical connector is assembled by the customer in the same way as described in... Fig. 1 described. It is pointed out that in the Fig. 1 In the illustrated embodiment, the grounding ring 2 can be designed as a shielding ring 19, and that in the Fig. 3 In the illustrated embodiment, the shield ring 19 can be designed as an earthing ring 2.

[0031] Fig. 4 shows an embodiment of an electrical connector with the locking unit 1 according to Fig. 3 The contact insert 11 is formed from the contact body 12 and the contact sleeve 13, each of which has a stop 17, 18. The contact insert 11 and the contact body 12 are fixed to each other via the contacts 9, for which retaining elements 16 are provided. Since the material of the contact insert 2 flows around the retaining elements 16 during assembly, a positive fit is achieved. In addition, retaining elements 16' are formed on an inner side of the contact sleeve 13.

[0032] The shielding is primarily achieved through the screw connections 21. The threaded ring 4 is mechanically and electrically connected to the shielding ring 2, and the latter to the union nut 3. Optionally, a wave spring washer can be provided between the union nut 3 and the threaded ring 4 to further improve the shielding.

[0033] Fig. 5 shows a further embodiment of an electrical connector according to the invention with the locking unit 1 according to Fig. 3 .

[0034] The contact insert 11 is designed in two parts, namely the contact body 12 and the contact sleeve 13. These are fixed by the retaining elements 16 of the contact 9, which are designed as circumferential retaining claws. The two parts of the contact insert 11 are thus connected via the contact 9, so that the locking unit 1 is captive and fixed between the stops 17, 18.

[0035] It can be clearly seen that probe area 14 and recording area 15, in contrast to the one in Fig. 4 The illustrated embodiment is relatively short. This means the entire inner diameter is available for design. This allows for greater wall thicknesses, which benefits both the manufacturing of the components, for example from plastic, and the product requirements. The shielding is carried out analogously to the description of Fig. 4 .

[0036] Fig. 6 Figure 1 shows a perspective view of the SPE connector, which has a pre-assembled electrical connector and a housing 22 with a cable gland. The cable gland has a pressure screw 23 and an internal clamping cage, which is not visible in this view.

[0037] The user assembles the connector as follows: First, the housing 22 with cable clamp is threaded onto the pre-cut cable. Then, the strands are exposed according to the assembly instructions and attached to the contacts 9, for example, by screwing them on. Next, the housing is attached to the locking unit 1, in particular by screwing it on. Finally, the pressure screw 23 is tightened, thus activating the internal cable clamp.

[0038] Fig. 7 shows a further embodiment of an electrical connector according to the invention with a housing 22 which is designed as an angled housing.

[0039] It is clearly evident that the locking unit 1 can be used with both a straight and an angled connector variant. Assembly is carried out analogously to the embodiment shown. Fig. 6

[0040] Regarding further advantageous embodiments of the devices and the method according to the invention, reference is made to the general part of the description and to the attached claims to avoid repetition.

[0041] Finally, it should be expressly pointed out that the exemplary embodiments of the devices and the method according to the invention described above serve only to discuss the claimed teaching, but do not limit it to these exemplary embodiments. Bezugszeichenliste

[0042] 1 Locking unit 2 Grounding ring 3 Union nut 4 Threaded ring 5 Recess (threaded ring) 6 Recess (grounding ring) 7 Retaining ring 8 Wave spring washer 9 Contact 10 Screw 11 Contact insert 12 Contact body 13 Contact sleeve 14 Probe area 15 Receiving area 16, 16' Retaining element 17 Stop (contact body) 18 Stop (contact sleeve) 19 Shielding ring 20 Snap element 21 Screw connection 22 Housing 23 Pressure screw 24, 24' O-ring

Claims

1. Electrical connector having a locking unit (1) and a contact insert (11) which is at least partially surrounded by the locking unit (1), wherein at least one contact (9) is arranged in and / or on the contact insert (11), wherein the contact insert (11) is formed in two pieces from a contact member (12) and a contact sleeve (13) which is connected to the contact member (12), wherein the contact member (12) and the contact sleeve (13) can be introduced into the locking unit at the connection side or at the plug side, characterised in that, at an outer side of the contact (9), at least one protruding retention element (16) is formed in order to produce a positive-locking and / or non-positive-locking connection between the individual components of the contact insert, that is to say, the contact member (12) and the contact sleeve (13), and the contact (9), and in that the two components of the contact insert (11) are connected by means of the contacts (9) so that the locking unit (1) is fixed in a non-releasable manner between a stop (17) of the contact member (12) and a stop (18) of the contact sleeve (13).

2. Electrical connector according to claim 1, characterised in that the contact member (12) has a probe region (14) which can be introduced into a receiving region (15) of the contact sleeve (13) or in that the contact sleeve (13) has a probe region (14) which can be introduced into a receiving region (15) of the contact member (12).

3. Electrical connector according to claim 1 or 2, characterised in that the contact member (12) is connected to the contact sleeve (13) in a positive-locking and / or non-positive-locking manner, and / or in that the contact (9) is connected to the contact member (12) and / or to the contact sleeve in a positive-locking and / or non-positive-locking manner.

4. Electrical connector according to any one of claims 1 to 3, characterised in that, at an inner side of the contact sleeve (13) and / or at an outer side of the contact member (12), at least one protruding retention element (16'), for example, a retention claw is formed in order to produce a positive-locking and / or non-positive-locking connection between the contact sleeve (13) and contact member (12).

5. Electrical connector according to any one of claims 1 to 4, characterised in that the at least one retention element (16) on the outer side of the contact (9) is in the form of a retention claw, and / or in that at an inner side of the contact insert (11) at least one protruding retention element (16), for example, a retention claw is formed in order to produce a positive-locking and / or non-positive-locking connection between the individual components (contact member 12 and contact sleeve 13) of the contact insert (11) and the contact (9).

6. Electrical connector according to any one of claims 1 to 5, characterised in that the contact insert (11) is connected to the locking unit (1) in a positive-locking and / or non-positive-locking manner.

7. Electrical connector according to any one of claims 1 to 6, characterised in that the contact member (12) is connected to the locking unit (1) by means of a securing element, for example, a screw.

8. Electrical connector according to any one of claims 1 to 7, characterised in that the stop (18) is formed on the contact sleeve (13) as an auxiliary positioning member.

9. Electrical connector according to any one of claims 1 to 8, characterised in that the contact (9) is connected to the contact member (12) and / or to the locking unit (1) by means of a securing element, for example, a screw.

10. Electrical connector according to any one of claims 1 to 9, characterised in that the locking unit (1) has a union nut (3) and a threaded ring (4), wherein the union nut (3) is connected to the threaded ring (4) by means of an earthing ring (2) or a shield ring (19).

11. Electrical connector according to claim 10, characterised in that both on the earthing ring (2) or the shield ring (19) and on the union nut (3) a stop (3) is formed in each case in order to produce a positive-locking connection.

12. Electrical connector according to claim 10 or 11, characterised in that both in the threaded ring (4) and in the earthing ring (2) or the shield ring (19) a recess (5, 6) is formed in each case and in that a securing ring (7) engages in these recesses (5, 6) in order to connect the threaded ring (4) to the earthing ring (2) or the shield ring (19).

13. Electrical connector according to any one of claims 10 to 12, characterised in that on the earthing ring (2) or the shield ring (19) at least one snap-fitting element (20) which engages behind a projection of the threaded ring (4) is formed.

14. Method for producing an electrical connector according to any one of claims 1 to 13, having the following method steps: - providing a contact sleeve (13), in particular inserting the contact sleeve (13) into an assembly tool, - pushing a locking unit (1) onto the contact sleeve (13), in particular as far as a stop of the contact sleeve (13), - inserting a contact member (12) into the locking unit (1) as far as the contact sleeve (13), in particular inserting a probe region of the contact member (12) into a receiving region of the contact sleeve (13), - inserting at least one contact (9) into the contact member (12).