Electrical contact element, prefabricated electrical cable and method of manufacturing

Description

[0001] The invention relates to an electrical contact element formed from a stamped and bent part or from a deep-drawn metal component, according to the preamble of claim 1.

[0002] The invention also relates to a pre-assembled electrical cable comprising an electrical conductor and an electrical contact element electrically and mechanically connected to the electrical conductor.

[0003] The invention further relates to a manufacturing method for producing an electrical contact element or a pre-assembled electrical cable.

[0004] Electrical contact elements for the direct connection of corresponding electrical mating contact elements are well-known in electrical engineering for a wide variety of applications. Electrical contact elements and their corresponding mating contact elements are used, among other things, in electrical connectors and mating connectors for direct electrical and mechanical contact. Various contact methods are available for this purpose.

[0005] In addition to contact elements that establish radial contact with the corresponding mating contact element (for example, pin contacts that are contacted on their outer surfaces by spring contact tabs), contact elements based on end-face contact are also used. A possible variant of such an end-face contact element is shown, for example, in DE 10 2021 122 611 A1. As a further example of end-face contact, reference is made to DE 36 00 456 A1, which discloses a contact part with a spring element having a convex end face on which the contact surface for contact with a mating contact is also formed.

[0006] The robustness of connectors and their contact elements is sometimes subject to high demands. In particular, a contact element must usually be suitable for a very high number of mating cycles. To meet these requirements, end contact elements are typically designed as solid bodies and therefore usually as turned parts.

[0007] Besides the robustness and durability of the contact elements, another common requirement is the economical production of these elements in high volumes. However, the manufacture of conventional end-contact elements involves considerable material, manufacturing, and assembly costs. The weight of these elements, especially when designed as solid turned parts, is also a significant factor.

[0008] For technical background, reference should also be made to WO 2012 / 141337 A1, which relates to a connector with a laterally contactable contact assembly in which a separate spring element is provided to generate sufficient contact pressure with a lance-shaped counter-contact element.

[0009] In view of the prior art, the object of the present invention is to provide an electrical contact element that can be manufactured cost-effectively, particularly in the context of mass production, and that is advantageously suited for end-face contacting, preferably with high mechanical stability.

[0010] The present invention also aims to provide an electrical cable pre-assembled with an electrical contact element, which can be manufactured cost-effectively, particularly in the context of mass production, and which is advantageously suitable for end-contacting, preferably with high mechanical stability.

[0011] Furthermore, it is an object of the invention to provide a manufacturing process with which an electrical end contact element or an electrical cable pre-assembled therewith can be manufactured cost-effectively, in particular in the context of mass production, with preferably high mechanical stability.

[0012] The problem is solved for the electrical contact element by the features listed in claim 1. With regard to the pre-assembled electrical cable, the problem is solved by the features of claim 13. Regarding the manufacturing process, the problem is solved by claim 14.

[0013] The dependent claims and the features described below relate to advantageous embodiments and variants of the invention.

[0014] An electrical contact element is provided, which is formed from a stamped and bent part and / or from a deep-drawn metal component.

[0015] The electrical contact element can be formed, in particular, by stamping and subsequent or simultaneous bending of a metal component (generally a predominantly flat metal component, especially a metal sheet) or by deep drawing of a corresponding metal component. A combination of the two manufacturing processes, i.e., stamping / bending and prior, simultaneous, or subsequent deep drawing of areas of the metal component, is also possible.

[0016] Preferably, the electrical contact element consists exclusively of the stamped / bent part or the deep-drawn metal component and has no other components. The electrical contact element is therefore preferably formed in one piece or monolithically, particularly preferably from a predominantly flat metal component / sheet.

[0017] Stamping and bending processes and deep drawing processes are well known in the prior art, which is why further details are omitted here. Both manufacturing processes are particularly suitable for the cost-effective production of connector components in mass production, but according to relevant experts, they are rather unsuitable for the production of end-contact elements due to a lack of mechanical stability.

[0018] According to the invention, the proposed electrical contact element has a contact area with an end contact surface designed for electrical and mechanical contact with an electrical counter-contact element.

[0019] The electrical contact element is thus advantageously designed for end-face contact and can therefore also be referred to as a "end-face contact element".

[0020] The counter contact element can also be designed as an end contact element, for example as a pin contact element, in particular as a spring-loaded pin contact element.

[0021] Preferably, the proposed contact element is a predominantly elongated component extending along a central or longitudinal axis. The longitudinal axis preferably also runs along the contact direction of the contact element with the corresponding mating contact element.

[0022] The contact area is preferably a front end section of the contact element, facing the mating contact element, along the longitudinal axis or contact direction. The contact area can extend from the front end of the contact element along the longitudinal axis towards the rear end of the contact element, away from the mating contact element.

[0023] The end contact surface of the contact area is formed particularly at the front end of the electrical contact element and faces the electrical counter-contact element.

[0024] According to the invention, the electrical contact element also has a support area which is arranged and configured on a side of the contact area facing away from the end contact surface to mechanically support the contact area. The contact area is integrally or monolithically connected to the support area via a primary connecting section.

[0025] The support area is arranged along the longitudinal axis of the electrical contact element, preferably extending from the front end of the contact element, behind the contact area. The support area preferably borders directly on the contact area along the longitudinal axis of the contact element.

[0026] By combining a contact element designed as a stamped and bent part and / or as a deep-drawn component with the aforementioned support area for the end-face contact area, it is advantageously possible to realize an end-face contact element that can be manufactured particularly cost-effectively in mass production while still exhibiting high mechanical stability. In this way, significant savings can be made in material and assembly costs as well as weight for the electrical contact element, without negatively impacting its service life or mechanical stability in practice.

[0027] The end contact surface can preferably be circular or round. However, alternative surface geometries are also possible (for example, a rectangular or square surface, an elliptical surface, a polygonal surface, etc.).

[0028] In an advantageous embodiment of the invention, it can be provided that the end contact surface is designed as a single, continuous surface.

[0029] However, the invention also allows for the end contact surface to be formed from several individual segments or surfaces. For example, the end contact surface can be divided into two parts, such as two contact tabs bent towards each other. A three-part, four-part, or even further subdivided end contact surface is also possible.

[0030] However, particularly high mechanical stability can be achieved if the end contact surface is continuous and preferably the entire contact area is monolithic or formed as a continuous area.

[0031] In principle, the end contact surface of the contact area can have any geometry or contour. For example, the end contact surface can be convex or concave. A counter-contact surface of the counter-contact element can then preferably be complementary, so that a predominantly planar contact between the contact element and the counter-contact element can occur.

[0032] According to a particularly preferred embodiment of the invention, however, it can be provided that the end contact surface is a predominantly flat surface.

[0033] The fact that the end contact surface is preferably a predominantly flat surface should not, however, preclude the possibility that one or more depressions (e.g., the centering bore mentioned below) or protrusions (e.g., a centering tip, for example, an indentation introduced from the back of the end contact surface) may optionally be formed in said flat surface. A counter-contact surface of the counter-contact element may preferably have a complementary structure, i.e., for example, a complementary protrusion or depression.

[0034] According to a further development of the invention, it can be provided, for example, that one or more bores are formed in the end contact surface.

[0035] The bore(s) can preferably be a blind hole. However, through holes may also be provided if necessary. The one or more bores may optionally have a chamfer or a transition radius to the end face.

[0036] According to a preferred embodiment, the end contact surface can have exactly one central centering bore, for example to center the corresponding mating contact element and / or to ensure greater stability of the connection in the contacted state by means of a section-wise positive locking mechanism and / or to support verification of the correct assembly of the contact element during connector assembly or cable assembly (e.g., by the centering bore supporting the centering of a mechanical test probe or by the centering bore being usable as an optical detection aid for optical verification of the correct positioning and / or alignment of the contact element).

[0037] It is also possible for the bores to be designed to accommodate one or more permanent magnets. A contact element equipped with magnets can facilitate contact with the mating contact element (e.g., enabling "blind mating") and / or provide magnetic coding so that contact is only possible with specific mating contact elements and / or only in one or more predetermined orientations.

[0038] It should be mentioned at this point that it is also possible, in principle, to integrate one or more mechanical coding means into the end contact surface or contact area, so that contacting is only possible with certain mating contact elements and / or only in one or more predetermined orientations.

[0039] Optionally, a contour can also be formed on the end contact surface, for example, a chamfer or rounding along the circumference of the end contact surface. A funnel-shaped shape of the end contact surface or contact area can also be provided.

[0040] In a further development of the invention, the support area can be partially annular, ring-shaped, or preferably at least substantially sleeve-shaped or wooden-cylindrical. In principle, however, the support area can be configured in any way to support the contact area from the rear, either sectionally or completely circumferentially. The support area can essentially have any geometry, including a spiral or star-shaped geometry. Furthermore, the support area can also support the contact area at a position spaced away from the edges or sides ("further inwards" instead of directly along the outer circumference).

[0041] Preferably, an annular or partially annular end of the sleeve-shaped support area, facing the contact area, mechanically supports the contact area on the side facing away from the end contact surface.

[0042] In a further development of the invention, it can be provided that the support area, in particular (but not exclusively) the sleeve-shaped support area, is formed from two support tabs or half-shells bent towards each other.

[0043] Preferably, the support tabs or half-shells, bent towards each other, touch at least partially along the longitudinal axis of the contact element when fully bent. The support area is therefore preferably closed at least substantially in the circumferential direction along the longitudinal axis of the contact element. In this way, particularly stable support and very high mechanical stability of the contact element can be achieved.

[0044] The support area can also be partially open in the circumferential direction, for example forming a U-shape or a V-shape.

[0045] In an advantageous embodiment of the invention, it can be provided that the primary connection section is designed as a bending point in order to form a transition angle between the support area and the contact area.

[0046] The transition angle can be, for example, 20° to 160°, preferably 45° to 135°, particularly preferably 80° to 100°, and in particular at least approximately 90° or exactly 90°.

[0047] The end contact surface is therefore preferably oriented at least substantially orthogonally to the longitudinal axis of the electrical contact element. However, the end contact surface can optionally be tilted relative to a perpendicular orientation, although this is less preferred.

[0048] Preferably, the longitudinal axis of the contact element runs centrally or centrically through the end contact surface.

[0049] According to the invention, the contact area is connected to the support area via at least one secondary connection section.

[0050] The secondary connection section is spaced apart from the primary connection section along the circumference of the end contact surface.

[0051] Whereas the contact area is integrally connected to the support area via the primary connection section, it is preferably provided that the connection via the secondary connection section is made in multiple parts, preferably by positive locking, force locking and / or material locking.

[0052] The secondary connection section can be a further section of the contact area or the support area, distinct from the primary connection section, in order to further stabilize the mechanical connection between the contact area and the support area and thus further increase the overall mechanical stability of the electrical contact element. The inclusion of at least one secondary connection section in addition to the primary connection section advantageously prevents, in particular, springback of the contact area or the end contact surface during contacting.

[0053] In principle, any number of secondary connection sections can be provided and arranged distributed along the circumference of the end contact surface.

[0054] The at least one secondary connection section can be integrally or monolithically connected to either the contact area or the support area (the connection with the other area can preferably be positive-locking, force-locking, and / or material-locking). If several secondary connection sections are provided, some of the secondary connection sections can optionally be connected to the contact area and others to the support area – therefore, it is not necessary for all secondary connection sections to be integrally connected to the same area. Optionally (less preferred), the secondary connection sections can also be provided that they are neither integrally connected to the contact area nor integrally connected to the support area and are therefore designed as completely independent components.

[0055] In a particularly advantageous embodiment of the invention, it can be provided that the secondary connecting section is formed as a connecting tab integrally connected with the contact area, which is bent in the direction of the support area and is connected to the support area at least positively along a longitudinal axis of the contact element.

[0056] The support area can form a corresponding positive-locking receptacle for the positive-locking connection with the secondary connecting section or the connecting tab, in particular a receptacle that can be engaged by the bent connecting tab of the contact area along the longitudinal axis of the contact element to enable locking of the contact area with the support area along the longitudinal axis. The connecting tab or the secondary connecting section can be designed accordingly to allow locking along the longitudinal axis in such a recess, for example by having a diameter change in the secondary connecting section or the connecting tab in the area of ​​the free end section. For this purpose, the secondary connecting section or the connecting tab can, for example, be designed at least substantially T-shaped.

[0057] Preferably, a connecting tab anchored on the end contact surface can be provided, which is bent over and threaded into a corresponding recess on the support area in a form-fitting manner, so that the form-fitting prevents an axial displacement of the end contact surface along the longitudinal axis of the contact element and thus a deflection of the contact area.

[0058] In an advantageous embodiment of the invention, it can be provided that the connecting tab of the secondary connecting section is directly connected to the support area at the connection points of the two half-shells.

[0059] In a particularly preferred embodiment, it can be provided that the connecting tab of the secondary connecting section forms a further positive locking in the circumferential direction with the sleeve-shaped support area, so that the half-shells of the support area are locked against each other.

[0060] In a further development of the invention, it can be provided that the secondary connection section has at least one welding or bonding point to connect the contact area with the support area.

[0061] As already mentioned, the connection of the secondary connecting section to the contact area or the support area can, in principle, be achieved in any way, with the positive locking described above being preferred, as this allows for particularly simple manufacturing. However, pressing, welding, bonding, or other joining techniques are also fundamentally possible and feasible within the scope of the present invention.

[0062] Typically, the support area can be designed to rigidly support the contact area along the longitudinal axis of the contact element. For many applications, rigid support is usually sufficient.

[0063] In a further development of the invention, it can also be provided that the support area elastically cushions the contact area along the longitudinal axis of the contact element.

[0064] It can therefore be provided that the contact element, or the end contact surface of the contact element, can spring back along the longitudinal axis of the contact element towards the end of the contact element furthest from the mating contact element when it is connected to the mating contact element. Such a spring-loaded end contact can improve the electrical and mechanical connection during operation of the contact assembly. In particular, it can ensure a high level of vibration resistance for the connector. Furthermore, it can reduce the risk of unintentional disconnection of the electrical and mechanical connection between the contact element and the mating contact element, and it can lower the contact resistance.

[0065] The elasticity between the support area and the contact area can be achieved, for example, by a support area that is at least partially elastic along the longitudinal axis of the contact element and / or by a primary connection section that is at least partially elastic and / or by a secondary connection section that is at least partially elastic. The respective tabs can be designed, among other things, as band-shaped or in the form of axially acting spring tabs (e.g., having a suitably appropriate width, length, and / or material thickness). For example, the connecting tab of the secondary connection section and / or a connecting tab of the primary connection section can also be bent or folded inwards in sections towards the longitudinal axis of the contact element to provide the necessary elasticity.

[0066] The connecting sections can be designed as lateral spring tabs. In this case in particular, it may be advantageous to connect at least one of the connecting sections, especially the secondary connecting section, to the support surface and / or the contact area via an additional weld or adhesive point in order to still allow for simple manufacturability within a stamping-bending process.

[0067] In a further training, it may be provided that the electrical contact element has a connection area for electrical and mechanical connection with an electrical conductor, in particular for electrical and mechanical connection with an inner conductor of an electrical cable.

[0068] Preferably, the connection area is integrally or monolithically connected to the support area and / or the contact area.

[0069] It can therefore be provided that the electrical contact element has, along its longitudinal axis, starting from the front end facing the mating contact element, the contact area, followed by the support area, and then the connection area. Optionally, further areas can also be formed between the aforementioned areas or at one of the ends of the electrical contact element.

[0070] The connection area is preferably a press or crimp section for direct connection to the electrical conductor. The connection area can, for example, have two crimp tabs which, in the delivery state, are initially partially bent towards each other in a trough shape and are then pressed or crimped into their final position on the electrical cable or conductor during final assembly.

[0071] The connection area could, for example, also be a soldering area for soldering to the electrical conductor of the electrical cable. In principle, the connection area can be designed to enable any form-fit, force-fit, and / or material-fit connection with the electrical conductor of the cable.

[0072] The invention also relates to a pre-assembled electrical cable comprising an electrical conductor and an electrical contact element electrically and mechanically connected to the electrical conductor according to the preceding and following embodiments.

[0073] The invention is particularly advantageous for use in the automotive sector, especially for camera solutions or for contacting PCB contact elements or for space-saving contacting of spring contact elements. In principle, however, the invention can be suitable for any application within the entire field of electrical engineering, especially for use with connectors.

[0074] In principle, the electrical cable can be any type of electrical cable that has at least one electrical conductor. In particular, the electrical cable can be designed to have an electrical conductor that is optionally directly enclosed by a cable sheath. The electrical conductor can be free of the cable sheath at its front end section to allow direct connection to the electrical contact element, especially via the aforementioned connection area.

[0075] For example, an electrical cable can be provided whose inner conductor is first encased by a dielectric, which in turn is surrounded by an outer conductor (for example, by a braided cable shield and / or a cable foil), which is then enclosed by the cable jacket. Alternatively to such a coaxial cable, a cable with multiple inner conductors can also be provided, for example, a differential cable or a twisted-pair cable. The specific cable type used is not essential within the scope of the invention.

[0076] The invention also relates to an electrical connector comprising at least one pre-assembled electrical cable according to the preceding and following embodiments. Optionally, the connector may also include an outer conductor contact element, a connector housing (preferably an electrically insulating housing), and / or other conventional connector components, such as locking and locking elements for connection with the corresponding mating connector.

[0077] Furthermore, the invention relates to an electrical contact arrangement comprising the electrical contact element according to the preceding and following embodiments, as well as the corresponding electrical counter-contact element, preferably an end contact element.

[0078] The invention further relates to a manufacturing process for producing an electrical contact element or an electrical cable pre-assembled with the contact element, comprising at least the following process steps: Providing a predominantly flat metal component; punching and bending the metal component and / or deep drawing the metal component to form a contact area with an end contact surface designed for electrical and mechanical contact with an electrical counter-contact element, as well as a support area which is arranged on a side of the contact area facing away from the end contact surface, is integrally connected to the contact area and is designed to mechanically support the contact area.

[0079] In contrast to known manufacturing processes for an end-contact element, the end-contact element does not need to be formed from a solid material. This enables particularly cost-effective production of the end-contact element. The proposed contact element, or the proposed pre-assembled electrical cable, is therefore particularly advantageous for applications requiring high-volume production, such as in the automotive sector. The proposed combination of contact area and support area ensures sufficient stability for the end-contact connection despite the simple manufacturing process.

[0080] As part of the aforementioned procedure, it may optionally be provided to introduce one or more bores into the end contact surface.

[0081] According to a further, optional process step, it may be provided to bend two support tabs towards each other so that these form two mutually bent half-shells to create a sleeve-shaped support area.

[0082] According to a further optional process step, it can be provided that the contact area is bent relative to the support area, preferably with a transition angle of at least approximately 90°.

[0083] According to a further method step of the invention, it is provided that the contact area is connected to the support area via at least one secondary connecting section, preferably by bending the secondary connecting section from the contact area towards the support area and in particular by forming a positive connection with the support area along the longitudinal axis of the contact element.

[0084] According to a further optional process step, an electrical cable with at least one inner conductor may be provided. The inner conductor may be stripped of its sheathing at a front end section either before or optionally during the manufacturing process described above. Again, optionally, the electrical contact element may be connected to the electrical cable, in particular via a connection area, preferably a crimp connection.

[0085] It should be emphasized that the process steps mentioned do not necessarily have to be carried out in the order in which they are first described or mentioned in the description or in the patent claims. Therefore, individual process steps or groups of process steps may be interchangeable, provided this is not technically impossible. Process steps may also be combined, divided into separate intermediate steps, or supplemented with intermediate steps. Furthermore, the process is not necessarily exhaustively described by the process steps described and may be supplemented with further process steps, including those not mentioned here.

[0086] Features described in connection with one of the subject matter of the invention, in particular those given by the electrical contact element, the pre-assembled electrical cable, the electrical connector, the electrical contact arrangement, or the manufacturing method, can also be advantageously implemented for the other subject matter of the invention. Likewise, advantages mentioned in connection with one of the subject matter of the invention can also be understood to relate to the other subject matter of the invention.

[0087] It should also be noted that terms such as "comprehensive," "exhibiting," or "with" do not exclude other characteristics or steps. Furthermore, terms such as "a" or "the," which indicate a singular number of steps or characteristics, do not exclude a plurality of characteristics or steps—and vice versa.

[0088] In a purist embodiment of the invention, however, it may also be provided that the features introduced in the invention with the terms "comprising," "comprising," or "with" are exhaustively listed. Accordingly, one or more lists of features within the scope of the invention may be considered complete, for example, for each claim. The invention may, for instance, consist exclusively of the features mentioned in claim 1.

[0089] It should be noted that designations such as "first" or "second" etc. are primarily used for the purpose of distinguishing between the respective device or process features and are not necessarily intended to indicate that features are mutually dependent or related to each other.

[0090] Furthermore, it should be emphasized that the values ​​and parameters described herein include deviations or fluctuations of ±10% or less, preferably ±5% or less, more preferably ±1% or less, and most preferably ±0.1% or less of the respective named value or parameter, provided that such deviations are not excluded in the practical implementation of the invention. The specification of ranges by initial and final values ​​also includes all those values ​​and fractions that are encompassed by the respective named range, in particular the initial and final values ​​and a respective mean value.

[0091] The invention also relates to an electrical end-contact element independent of claim 1, which is formed from a stamped and bent part or from a deep-drawn metal component. The further features of claim 1 and the dependent claims, as well as the features described in this description, relate to advantageous embodiments and variants of this end-contact element and can be combined arbitrarily with the end-contact element mentioned herein. The applicant explicitly reserves the right to claim such an end-contact element separately.

[0092] Exemplary embodiments of the invention are described in more detail below with reference to the drawings.

[0093] The figures each show preferred embodiments in which individual features of the present invention are combined with one another. Features of an embodiment can also be implemented independently of the other features of the same embodiment and can therefore be readily combined by a person skilled in the art to form further meaningful combinations and subcombinations with features of other embodiments.

[0094] In the figures, functionally identical elements are provided with the same reference symbols.

[0095] They show schematically: Figure 1 shows a stamped, initially unbent metal sheet from which an electrical contact element can be produced according to a first embodiment of the invention; Figure 2 shows the electrical contact element according to the first embodiment after bending the metal component. Figure 1 Figure 3 with the electrical contact element of the Figure 2A pre-assembled electrical cable according to an embodiment of the invention; Figure 4: an electrical contact element according to a second embodiment of the invention, with a predominantly square end contact surface; Figure 5: an electrical contact element according to a third embodiment of the invention, with a predominantly square end contact surface and a support area that is only partially closed in the circumferential direction; Figure 6: an electrical contact element according to a fourth embodiment of the invention, with a weld point between the secondary connection section and the support area; Figure 7: an electrical contact element according to a fifth embodiment of the invention, with a locator bore in the end contact surface; Figure 8: an electrical contact element according to a sixth embodiment of the invention, with a contouring of the end contact surface along the circumference;Figure 9 shows an electrical contact element according to a seventh embodiment of the invention, with a two-part end contact surface; Figure 10 shows an electrical contact element according to an eighth embodiment of the invention, with an additional positive locking mechanism between the half-shells of the support area for mutual locking of the half-shells; and Figure 11 shows an electrical contact element according to a ninth embodiment of the invention, with an elastic support of the contact area.

[0096] In Figure 1 A flat metal component 1 or a metal sheet is shown in dashed lines, which has been pre-processed into a blank 2 of an electrical contact element 3 according to a first embodiment of the invention by a stamping process. In a subsequent bending process, the blank 2 is finally formed into the electrical contact element 3, which is Figure 2The electrical contact element 3 is therefore formed from a stamped and bent part in the following figures and embodiments. However, it is also possible, alternatively or additionally, to form the electrical contact element 3 from a deep-drawn part or a deep-drawn metal component. The present embodiments are therefore not to be understood as limiting.

[0097] Figure 3 Finally, the electrical contact element 3 of the first embodiment of the invention is shown in a mounted state on an electrical conductor 4 of a correspondingly pre-assembled electrical cable 5.

[0098] The electrical contact element 3 of the first embodiment is subsequently described essentially in conjunction with the Figures 1 to 3 described.

[0099] The electrical contact element 3 has a contact area 6 with an end contact surface 7 designed for electrical and mechanical contact with an electrical mating contact element (not shown). The end contact surface 7 is arranged along the longitudinal axis L of the contact element 3 at the front end of the contact element 3, which faces the mating contact element for electrical and mechanical contact. In the exemplary embodiments, the end contact surface 7 is primarily a flat surface, but may optionally also be curved. The contact area 6 itself is essentially flat or disc-shaped in the exemplary embodiments.

[0100] The contact element 3 has a support area 8, which is arranged on a side of the contact area 6 facing away from the end contact surface 7. The support area 8 is designed to mechanically support the contact area 6 and is integrally connected to the contact area 6 via a primary connecting section 9 (see in particular [reference]). Figure 1 ).

[0101] In the Figures 1 to 3In the illustrated embodiment, the support area 8 is primarily sleeve-shaped, i.e., preferably at least substantially completely closed along the circumferential direction of the end contact surface 7. An annular or at least partially annular end of the sleeve-shaped support area 8, facing the contact area 6, is thus advantageously able to mechanically support the contact area 6 on the side facing away from the end contact surface 7. In the illustrated embodiments, the sleeve-shaped support area 8 is formed from two mutually bent half-shells 10.

[0102] In the exemplary embodiments, the end contact surface 7 is oriented orthogonally to the longitudinal axis L of the contact element 3. For this purpose, the primary connection section 9 is designed as a bending point to create a corresponding transition angle α (see figure). Figure 1) between support area 8 and contact area 6, preferably a transition angle α of at least approximately 90°, as shown.

[0103] For connection with the electrical conductor 4, the contact element 3 optionally also has a connection area 11, in the exemplary embodiments a crimp area which is preferably integrally connected to the support area 8, as in particular in Figure 1 The connection area 11 can be formed from two crimp tabs 12 which are bent towards each other in a trough-like shape in a pre-assembly state (cf. Figure 2 The subsequent crimped state with the electrical conductor 4 of cable 5 is in Figure 3 depicted.

[0104] To optionally further improve the mechanical stability of the contact element 3, in particular to prevent deflection of the end contact surface 7 along the longitudinal axis L of the contact element 3, the contact area 6 is connected to the support area 8 via at least one secondary connecting section 13 in the exemplary embodiments. The secondary connecting section 13 is spaced apart from the primary connecting section 9 along the circumference of the end contact surface 7, for example, along the circumferential direction of the end contact surface 7 on the side opposite the primary connecting section 9, as shown in the figures.

[0105] The secondary connecting section 13 is integrally connected to the contact area 6 and forms a connecting tab 14, which is bent towards the support area 8 to engage in a positive fit with the support area 8 along the longitudinal axis L of the contact element 3. For this purpose, the connecting tab 14 of the secondary connecting section 13 is essentially T-shaped or has a diameter change at its free end section to engage a corresponding recess 15 in the support area 8. In the exemplary embodiments, the recess 15 in the support area 8 is divided into two parts and distributed as a first partial recess 15a and a second partial recess 15b on the respective half-shells 10 (see Figure 1). Figure 1 ).

[0106] In the Figures 4 to 11Further possible embodiments of an electrical contact element 3 according to the invention are shown as examples, wherein the individual features can also be implemented in combination with each other, provided that this is not technically excluded.

[0107] Based on Figure 4 This is intended to illustrate by way of example that, within the framework of the overall concept according to the invention, basically any geometry can be provided for the contact area 6 or for the end contact surface 7. The end contact surface 7 therefore does not necessarily have to be round, as shown in the first embodiment, but can, among other things, have a rectangular, square, elliptical or any polygonal cross-section. By way of example, the Figures 4 and 5an at least approximately square geometry is represented. Accordingly, the support area 8 can also have a corresponding geometry (rectangular / square), whereby a support of the square contact area 6 of the Figure 4 for example, it could also be achieved by a sleeve-shaped support area 8 with a round cross-section, as in Figure 2 The geometry of the support area 8 does not necessarily have to correspond to the geometry of the contact area 6 - neither in shape nor size or diameter.

[0108] In Figure 5This example demonstrates that sufficient support of the contact area 6 can also be achieved if the support area 8 is not completely closed in the circumferential direction of the end contact surface 7, but is, for example, U-shaped. In principle, many different configurations of the support area 8 are possible that can lead to sufficient support of the contact area 6. Also Figure 5 It therefore serves only to illustrate one of many variations.

[0109] In Figure 6 An example of a connection between the secondary connecting section 13 or the connecting tab 14 of the secondary connecting section 13 and the support area 8 is shown, in which a material-bonded connection is used as an alternative to the positive locking described above. A weld point 16 is shown as an example. Figure 6shown, which in addition to connecting the contact area 6 to the support area 8 can also enable the two half-shells 10 of the support area 8 to be secured to each other.

[0110] Based on Figure 7 This example illustrates that the end contact surface 7 may optionally have one or more bores, for example, a central centering bore 17, which can function, among other things, as a locator bore. Bores may also be useful for connecting one or more permanent magnets to the contact element 3 (not shown), thus facilitating contact with the mating contact element, for example, to enable blind connection, or to provide magnetic coding for connection with a corresponding mating contact element. Mechanical coding means may also be provided.

[0111] Based on Figure 8 It should be made clear that the contact area 6 or the end contact surface 7 may also be contoured. An example is shown in Figure 8 A rounding 18 is shown along the circumference of the end contact surface 7. A chamfer may also be provided if necessary. This can, for example, enable centering in a correspondingly designed mating contact element.

[0112] Based on Figure 8 It also follows that the diameter of the end contact surface 7 does not necessarily have to correspond to the diameter of the support area 8 or the sleeve-shaped support area 8 in order to provide sufficient support.

[0113] In the preceding embodiments, the end contact surface 7 is in each case designed as a single, continuous surface. However, this is not absolutely necessary, as shown by Figure 9This should be made clear. In Figure 9 The end contact surface 7 is formed from two contact tabs 19 bent towards each other, each of which is integrally or monolithically connected to the support area 8 or the respective associated half-shells 10 of the support area 8 via a respective primary connecting section 9. In principle, a further subdivision of the end contact surface 7 is also possible, although for reasons of mechanical stability a single, continuous end contact surface 7 is generally preferred.

[0114] To further prevent the half-shells 10 of the sleeve-shaped support area 8 from springing up, in addition to the previously presented variant of a weld or adhesive point, a further positive locking connection in the circumferential direction of the sleeve-shaped support area 8 can also be provided, which is provided by a correspondingly designed connecting tab 14 of the secondary connecting section 13, as shown in Figure 10 as shown. In this way, on the one hand the contact area 6 can be locked against the support area 8 and on the other hand the two half-shells 10 of the support area 8 can be locked against each other.

[0115] It should be mentioned at this point that, as an alternative to the "watchtower-like" geometry of the connecting tab 14 of the secondary connecting section 13 of the Figure 10 Alternative geometries may also be provided to enable the double positive locking mechanism.

[0116] The embodiments of the invention proposed above each show a rigid or inelastic support of the contact area 6 by the support area 8. Alternatively, depending on the application, it may also be provided that the support area 8 elastically supports the contact area 6 along the longitudinal axis L of the contact element 3. In this way, a spring-loaded end contact element can be provided. This can be achieved, for example, by omitting the secondary connecting section 13 in order to deliberately allow the contact area 6 to deflect towards the support area 8. In this case, the support area 8 merely forms an end stop for the support and provides the contact area 6 with a certain elastic clearance along the longitudinal axis L in a defined section.

[0117] Another option for elastic support is in Figure 11The connecting tabs 14 of the primary connecting section 9 and the secondary connecting section 13 are each designed as spring tabs. In this embodiment, the primary connecting section 9 can still be integrally connected to the support area 8 and the contact area 6, wherein the secondary connecting section 13 is preferably optionally connected to the contact area 6 or the support area 8 by an additional weld point 16, adhesive point, or crimp, after the blank 2 has been inserted into the Figure 11 The depicted shape was bent.

Claims

1. Electrical contact element (3) which is formed from a stamped and bent part and / or from a deep-drawn metal component (1), comprising - a contact area (6) having an end-face contact surface (7) designed for electrical and mechanical contacting with an electrical mating contact element; and - a support area (8) which is arranged on a side of the contact area (6) facing away from the end-face contact surface (7) and is designed so as to mechanically support the contact area (6), wherein the contact area (6) is integrally connected to the support area (8) via a primarily connecting section (9), characterized in that the contact area (6) is connected via at least one secondary connecting section (13) to the support area (8) which is at a distance from the primary connecting section (9) along the circumference of the end-face contact surface (7).

2. Electrical contact element (3) according to Claim 1, characterized in that the end-face contact surface (7) is designed as a single, continuous surface.

3. Electrical contact element (3) according to Claim 1 or 2, characterized in that the end-face contact surface (7) is a primarily flat surface.

4. Electrical contact element (3) according to one of claims 1 to 3, characterized in that in the end-face contact surface (7) one or more holes are formed, preferably a central centering hole (17).

5. Electrical contact element (3) according to one of claims 1 to 4, characterized in that the support area (8) is primarily sleeve-shaped, wherein preferably an annular or in part annular end of the sleeve-shaped support area (8) facing the contact area (6) mechanically supports the contact area (6) on the side facing away from the end-face contact surface (7).

6. Electrical contact element (3) according to Claim 5, characterized in that the sleeve-shaped support area (8) is formed from two half shells (10) which are bent towards each other.

7. Electrical contact element (3) according to one of claims 1 to 6, characterized in that the primary connecting section (9) is designed as a bending point so as to form a transition angle (α) between the support area (8) and the contact area (6), preferably a transition angle (α) of at least approximately 90°.

8. Electrical contact element (3) according to one of claims 1 to 7, characterized in that the secondary connecting section (13) is formed integrally with the connecting tab (14) which is connected to the contact area (6) and is bent in the direction of the support area (8) and is connected in a positive-locking manner to the support area (8) along the longitudinal axis (L) of the contact element (3).

9. Electrical contact element (3) according to claim 6 and 8, characterized in that the connecting tab (14) of the secondary connecting section (13) is connected to the support area (8) at the connection sites of the half shells (10) and forms a further positive-locking connection in the circumferential direction of the sleeve-shaped support area (8) so that the half shells (10) of the support area (8) are locked against each other.

10. Electrical contact element (3) according to one of claims 1 to 9, characterized in that the secondary connecting section (13) has at least one welding point (16) or bonding point in order to connect the contact area (6) to the support area (8).

11. Electrical contact element (3) according to one of claims 1 to 10, characterized in that the support area (8) provides an elastic cushioning support of the contact area (6) along a longitudinal axis (L) of the contact element (3).

12. Electrical contact element (3) according to one of claims 1 to 11, characterized by a connection area (11) for electrical and mechanical connection to an electrical conductor (4), in particular an inner conductor of an electrical cable (5), which is integrally connected to the support area (8) and / or the contact area (6).

13. Pre-assembled electrical cable (5), comprising an electrical conductor (4) and an electrical contact element (3) electrically and mechanically connected to the electrical conductor (4), as claimed in one of claims 1 to 12.

14. Manufacturing method, comprising at least the following method steps: - providing a primarily flat metal component (1); - stamping and bending the metal component (1) or deep-drawing the metal component (1) in order to form a contact area (6) having an end-face contact surface (7) designed for electrical and mechanical contacting with an electrical mating contact element, and a support area (8) which is arranged on a side of the contact area (6) facing away from the end-face contact surface (7), is integrally connected to the contact area (6) and is designed so as to mechanically support the contact area (6) characterized by at least the following additional method step: - connecting the contact area (6) to the support area (8) via at least one secondary connecting section (13).

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