Electric cable or electric wire provided with a plug contour for directly plugging into a mating plug

Abstract

The invention relates to a cable or a wire and to a method for producing a plug contour (10) on an end (21) of an electric wire (20), in particular a stranded wire, having the following steps: a. forming, in particular press-forming, the electric wire at the end (23) of the wire, thereby forming a plug portion (21) with at least one flat surface portion (22a, 22b) at said end (23), b. providing a contact band (30), said contact band (30) having a plurality of elastic contact lamellas (31) protruding from the contact band (30), and c. applying and connecting the contact band (30) to the surface portion (22a, 22b).

Description

[0001] Electrical cable or electrical line designed with a plug-in contour for direct insertion into a mating connector

[0002] Description:

[0003] The invention relates to electrical cables or electrical lines designed with a plug-in contour for direct insertion into a plug-in receptacle, e.g. on a mating connector, an interface, a contact socket or a plug. In the prior art, there is no uniform terminology for plugs and sockets or male contacts and female contacts. In the terminology of the present invention, either male or female contacts can be used in a plug or socket. Male contacts are generally non-resilient contact geometries, such as contact pins, contact pins, flat contacts or the like. Female contacts are resilient contacts in which at least one resilient contact element is present which is involved in making contact with a mating contact.

[0004] A plug connection is therefore realized by a plug and a mating plug, whereby the respective plugs and mating plugs optionally contain corresponding or interacting spring-loaded contacts and non-spring-loaded contact parts.

[0005] Furthermore, a variety of connection solutions are known in the prior art for connecting an electrical contact element to an electrical line, e.g., a stranded conductor. Conventional techniques such as soldering, welding, crimping, and the like will not be discussed in this disclosure, as these methods are sufficiently described in the prior art and normatively in the IEC 60325 series of standards.

[0006] DIN EN 60352-2 contains requirements, tests and application notes for solderless crimp connections made with stranded wire conductors of 0.05 mm 2 up to 10 mm 2cross-section or with solid conductors from 0.25 mm to 3.6 mm diameter and with suitable non-insulated or pre-insulated crimp sleeves.

[0007] Significantly larger cable cross-sections cannot currently be easily connected to a contact element in an efficient and cost-effective manner. Not only the manufacturing technology, but also the contact geometry and design are complex and expensive.

[0008] Increasingly, alternative drive components in automotive engineering are being designed with pluggable electrical connections to facilitate assembly and service. The highest demands are placed on the connectors in terms of electrical contact properties, resilience, sealing, and installation space.

[0009] DE 10 2013 004 708 A1 relates to an electrical stranded conductor made of copper for the parallel and / or serial contacting of circular plug contacts with a conductor cross-section, wherein at least one section of the stranded conductor has a section with a reduced cross-section and a cylindrical circular plug contact socket or a cylindrical circular plug contact pin is welded to this section.

[0010] Another significant problem in the state of the art is the use of copper as a connecting material, since copper is difficult or not reliable to weld to a contact element, as required in the automotive industry.

[0011] If, for example, the detachable plug contacts are made of a first material that is different from copper or has an alloy in which copper is only present in reduced quantities, a particular problem arises in connecting the plug contacts to the copper conductor.

[0012] In the current state of the art, crimp connections are therefore primarily used to establish a secure connection.

[0013] The present invention is therefore based on the object of providing a solution for making simple and cost-effective contact between an electrical interface and an electrical line.

[0014] This problem is solved by the combination of features according to patent claim 1.

[0015] A basic idea of ​​the invention is to modify a conventional electrical line (cable) in such a way that the line itself or the line end is designed as a plug-in contour. According to the invention, a method for producing such a plug-in contour at a line end of an electrical line, in particular a stranded line, is proposed, comprising the following steps: a. Shaping, in particular press-forming, of the electrical line at the line end to form a (preferably compacted) plug-in section with at least one flat surface section at this line end, b. Providing a contact strip (contact lamella strip), wherein the contact strip has a plurality of resilient contact lamellas protruding from the contact strip, and c. Applying and connecting the contact strip to the surface section.

[0016] Furthermore, the invention proposes a method for producing a plug-in contour at a line end of an electrical line, in particular a stranded line, comprising the following steps: a. forming, in particular press-forming, the electrical line at the line end to form a (preferably compacted) plug-in section with at least one flat surface section at this line end, b. providing a contact strip (contact lamella strip), wherein the contact strip has a plurality of resilient contact lamellas protruding from the contact strip, and c. applying and connecting the contact strip to the surface section.

[0017] In the method, at least one fastening element for a correspondingly designed mating connector is further formed in the flat surface section and / or directly adjacent to the flat surface section, in particular by means of forming and / or separating, further in particular punching, and / or a contact strip is provided with the at least one fastening element.

[0018] Furthermore, the term "electrical cable" also includes an electrical conductor, such as a rigid busbar. Instead of compacting or reshaping an electrical cable, it is also conceivable to use a (solid) busbar and then perform steps b) and c) on the surface of the busbar.

[0019] The contact strip must be applied in such a way that the contact lamellas protrude on the upper side opposite the connection side and can act as spring-loaded lamellas when plugged together with a mating plug element.

[0020] It is further preferred if the electrical cable has a substantially round cross-sectional shape in the adjacent, non-formed region of the cable adjoining the formed region. Round, in the sense of the present invention, refers to a cross-sectional shape of typical round cables, which is not always perfectly round but approximately round.

[0021] In a further advantageous embodiment of the invention, it is provided that a substantially cuboid-shaped conductor section is formed, preferably compacted, during the forming process. This should be done in such a way that the strands of the stranded conductor are locally bonded and pressed together, which can be achieved in particular by a compacting process.

[0022] It is therefore further advantageous if the cable end is processed by compaction and, in particular, shaped into a form in which the plug-in section is formed with a flat upper side and a flat lower side substantially parallel to the upper side. This provides a simple plug-in contour in a basic shape suitable for a plug-in process.

[0023] In a further advantageous embodiment of the invention, it is provided that such a contact strip is provided in which a plurality of contact lamellas arranged in parallel are provided and the contact lamella strip is applied to one of the surface sections at the cable end in such a way that the parallel contact lamellas are oriented either along or transversely, in particular 90° transversely to the cable extension direction.

[0024] Alternatively, a design is conceivable in which such a contact strip is provided in which several contact blades are arranged in parallel, and the contact blade strip is applied to one of the surface sections at the cable end such that the parallel contact blades are oriented at an angle of 30° to 60°, preferably 45°, and / or 120° to 150°, preferably 135°, to the cable extension direction (L). Such an orientation of the contact blades at a corresponding angle to the cable extension direction advantageously allows the electrical cable to be plugged in both in the cable extension direction and at 90°.

[0025] A further aspect of the present invention relates, in addition to the described method, to an electrical line, in particular an electrical stranded conductor having a line end which forms a plug-in section which has at least one flat, in particular planar, surface section, as well as at least one contact strip applied directly to the surface section and connected thereto, wherein the contact strip has a plurality of (elastically) resilient contact lamellae protruding therefrom.

[0026] Furthermore, the invention proposes an electrical cable, in particular a stranded electrical conductor, comprising a cable end forming a plug-in section having at least one flat, in particular planar, surface section, and at least one contact strip applied directly to the surface section and connected thereto, wherein the contact strip has or has a plurality of (elastically) resilient contact blades protruding therefrom. Furthermore, the plug-in section of the cable end has at least one fastening element for a correspondingly designed mating connector. In this case, the at least one fastening element is, in particular, a latching element and / or a locking element.

[0027] The advantage of this is that the fastening element provides a primary locking device for the cable in a simple, cost-effective and space-saving manner (in particular directly on the plug-in section), which fixes the cable against any pull-out force acting on the cable. An insulating body for the cable is fastened in the correspondingly designed mating connector, in particular in a plug housing of the correspondingly designed mating connector. Alternatively, the mating connector can also form and / or comprise the insulating body. Furthermore, it is advantageous that no additional parts or components are required for fastening the cable in the mating connector. In other words: the electrical cable can be fastened or fastened, in particular primarily latched or primarily locked, directly in or on the mating connector by means of the fastening element at the cable end.In this way, a particularly compact and small, easy-to-manufacture and cost-effective connector consisting of a plug and mating plug can be provided.

[0028] In an advantageous embodiment of the invention, it is provided that the at least one fastening element is formed in the flat surface section and / or directly adjacent to the flat surface section. In this case, the fastening element is in particular a recess, more particularly a groove-like recess.

[0029] In one embodiment, the cable according to the invention is designed such that at least one contact strip has at least one fastening element. Furthermore, the at least one fastening element is designed, shaped, or configured in particular as a spring element, a pin, a pin, and / or a bayonet-type closure element.

[0030] In an advantageous embodiment of the cable, it is provided that the electrical cable has a substantially round cross-sectional shape in the adjacent non-formed region of the cable adjoining the end plug-in section.

[0031] A further advantageous solution is one in which the contact strip has a web on the edge side in at least one edge region, to which the plurality of contact lamellas are connected on one side and the other (opposite) end of the contact lamellas is designed as a free end.

[0032] The contact blades can advantageously be bent in a spoon-shaped manner, so that the contact point of the respective contact blade is located approximately in the middle of the surface section in the direction of the contact blade extension, and the ends of the contact blades end at or slightly above the surface sections. To illustrate the preferred blade configuration, reference is made to the figure in the description of the exemplary embodiments. In principle, however, other blade shapes are also conceivable. In any case, according to the concept of the invention, it is advantageous if several, in particular 3, 4, 5, 6, or 7, blades are arranged next to one another.

[0033] An alternative embodiment provides for two opposing surface sections to be formed on the plug-in section, and preferably a contact strip connected to each surface section is applied and secured. The contact blades can be aligned in a mirror image or in opposite directions.

[0034] In an advantageous embodiment of the cable, it is further provided that at least one contact strip protrudes laterally and / or at the front with a projection beyond the outer contour of the plug-in section, so that the respective projection forms a contact or stop surface for interaction with a counter-surface on a corresponding mating connector shaped accordingly for mating. A defined projection can optimize the joining and mating with the mating connector element.

[0035] The connection of the contact strip is advantageously effected in a material-locking manner, particularly preferably at a plurality of connection points.

[0036] The concept of the invention is particularly suitable for electrical cables that have a cable sheath. In the method according to the invention, the cable sheath is removed in a defined end section before compacting or generally forming, and the remaining cable sheath can also serve as a stop for determining the insertion depth.

[0037] According to the invention, a connector with a plug and a correspondingly designed mating plug is also proposed. The plug is an electrical line, in particular a stranded electrical conductor, having a line end forming a plug-in section having at least one flat surface section, as well as at least one contact strip applied directly to the surface section and connected to it. Furthermore, the contact strip has a plurality of contact blades, in particular elastically resilient, protruding from it. The plug-in section of the line end has at least one fastening element for the correspondingly designed mating plug. Furthermore, the at least one fastening element is, in particular, a latching element and / or a locking element.

[0038] In an advantageous embodiment, the mating connector is formed in two parts, and each part of the two-part mating connector has a complementary fixing means. This allows the two parts of the two-part mating connector to be secured to each other.

[0039] Other advantageous developments of the invention are characterized in the subclaims or are presented in more detail below, together with the description of the preferred embodiment of the invention, with reference to the figures. They show:

[0040] Fig. 1 shows a line section according to the invention with a plug-in contour;

[0041] Fig. 2 shows an alternative embodiment of a cable according to the invention with a plug-in contour;

[0042] Fig. 3 is a frontal schematic view of a plug-in contour according to the invention;

[0043] Fig. 4 is a plan view of the embodiment analogous to Figure 3;

[0044] Fig. 5 shows a top and side view of an alternative contact strip; Fig. 6a shows a perspective view of an electrical line;

[0045] Fig. 6b is a sectional view of the electrical cable arranged in a mating connector;

[0046] Fig. 7a is a perspective view of another electrical line;

[0047] Fig. 7b is a sectional view of the further electrical line arranged in a mating connector;

[0048] Fig. 8a is a perspective view of yet another electrical line;

[0049] Fig. 8b is a sectional view of yet another electrical line arranged in a mating connector;

[0050] Fig. 9 shows a further alternative embodiment of a cable according to the invention with a plug-in contour.

[0051] The figures are merely illustrative and schematic. Identical reference numerals in the figures indicate identical functional and / or structural features.

[0052] Figures 1 and 2 show two exemplary embodiments of a pluggable cable 20. Each shows a section of an electrical cable 20 with the cable end 23 having a plug-in contour 10, which forms a plug-in section 21.

[0053] In both Figures 1, the plug-in section 21 has a cuboid shape and an upper and lower flat surface section 22a, 22b, which are diametrically opposite each other.

[0054] A contact strip 30 is firmly attached to the upper surface section 22a, as can be seen in Figure 4, and connected at several firmly bonded connection points. Furthermore, it can be seen that the contact strip 30 has several (three in each of Figures 1 and 2) (elastically) resilient contact blades 31 protruding therefrom. The contact blades 31 protrude upwards so that they are provided with a mating contour for resilient contact during the plugging process. Due to the resilient properties, a contact force is obtained that depends on the number of contact blades and their resilient properties.

[0055] Furthermore, it can be clearly seen in Figures 1 and 2 that the electrical line 20 in the adjacent non-formed region 24 of the line 20 adjoining the end plug-in section 21 has a substantially round cross-sectional shape and is formed with a cable sheath 26.

[0056] Figure 5 shows a design of a contact strip 30. This strip has a web 32 on at least one edge region, to which the plurality of contact blades 31 are connected at one end, and the other (opposite) end 34 of the contact blades 31 is designed as a free end. This results in resilient contact arms, which also have a shape as shown in the adjacent view.

[0057] In Figure 3, two opposing surface sections 22a, 22b are formed on the plug-in section 21, and on each surface section 22a, 22b, a contact strip 30 connected to the latter is applied and fastened, with the contact blades 31 being arranged in opposite directions. A mirror-image arrangement would be possible as an alternative. It can also be seen that the contact strip 30 protrudes laterally beyond the outer contour of the plug-in section 21 with a projection 35, so that the respective projection 35 forms a contact and stop surface for interacting with a counter-surface on a corresponding mating connector shaped accordingly for mating. Such a design can also be seen in Figures 1 and 2.

[0058] The contact strip 30 shown has a plurality of (elastically) resilient contact lamellae 31 protruding from it.

[0059] The orientation of the contact blades 31 in the embodiment of Figure 1 is parallel to the cable extension direction L and in Figure 2 at a 90° angle transverse thereto. A further alternative embodiment of a cable 20 according to the invention with a plug-in contour 10 at the cable end 23 of the cable 20 is shown in Figure 9, in which such a contact strip 30 is provided in which a plurality of parallel contact blades 31 are provided and the contact strip 30 is applied to one of the surface sections at the cable end such that the parallel contact blades 31 are oriented at an angle of 45° and / or 135° to the cable extension direction L.

[0060] Figure 6a shows a perspective view of an electrical line 20, which is designed as an electrical stranded conductor. The electrical line 20 has a line end 23, which forms a plug-in section 21 having at least one flat surface section 22a, 22b, as well as a contact strip 30 applied directly to the surface section 22a, 22b and connected to it. In addition, the contact strip 30 has a plurality of elastically springy contact blades 31 protruding from it. Furthermore, the plug-in section 21 of the line end 23 has two fastening elements 50 for a correspondingly designed mating connector 60. The respective fastening element 50 is, for example, a latching element and / or a locking element in the form of a groove-like punched recess. Furthermore, the respective fastening element 50 is formed in the flat surface section 22a, 22b.

[0061] Figure 6b shows a sectional view of the electrical cable 20 shown in Figure 6a arranged in a correspondingly designed mating connector 60. In the assembled state shown, the plug-in section of the cable 20 is completely received in the mating connector 60 and locked with the respective fastening element 50 in the mating connector 60. The mating connector is formed in two parts, and respective parts of the two-part mating connector 60 have a mutually complementary fixing means for fixing the two parts of the mating connector 60 to one another.

[0062] Figure 7a shows a perspective view of another electrical line 20, which is designed as an electrical stranded conductor. The electrical line 20 has a line end 23, which forms a plug-in section 21 having at least one flat surface section 22a, 22b, as well as a contact strip 30 applied directly to the surface section 22a, 22b and connected thereto. In addition, the contact strip 30 has a plurality of elastically springy contact blades 31 protruding therefrom. Furthermore, the contact strip 30 has a fastening element 50. The fastening element 50 is designed here, for example, as a pin and / or bayonet closure element protruding from the one flat section 22a.

[0063] Figure 7b shows a sectional view of the further electrical line 20 shown in Figure 7a, arranged in a correspondingly designed mating connector 60. According to Figure 7b, a corresponding contact strip 30 with a corresponding fastening element 50 is also arranged on the other flat section 22. In the assembled state shown, the plug-in section of the line 20 is completely received in the mating connector 60 and secured with the respective fastening element 50 in the correspondingly designed mating connector 60. The mating connector is designed in two parts, and respective parts of the two-part mating connector 60 have a mutually complementary fixing means for fixing the two parts of the mating connector 60 to one another.

[0064] Figure 8a shows a perspective view of yet another electrical line 20, which is designed as an electrical stranded conductor. The electrical line 20 has a line end 23, which forms a plug-in section 21 having at least one flat surface section 22a, 22b, and a contact strip 30 applied directly to the surface section 22a, 22b and connected thereto. In addition, the contact strip 30 has a plurality of elastically springy contact blades 31 protruding therefrom. Furthermore, the contact strip 30 has a fastening element 50, which extends from the flat surface section 22a in a transverse direction of the line 20 beyond the respective side edge of the line end 23 along a side surface of the line end 23. In the region of the side surface of the line end, the fastening element has a spring element which protrudes from the side wall of the line end.

[0065] Figure 8b shows a sectional view of the further electrical line 20 shown in Figure 8a arranged in a correspondingly designed mating connector 60. In the assembled state shown, the plug-in section of the line 20 is completely received in the mating connector 60 and is rusted with the respective fastening element 50 in the correspondingly designed mating connector 60, which for this purpose has at least one correspondingly designed projection and / or stop and / or undercut for the fastening element 50, in particular the respective spring element.

Claims

Claims: A method for producing a plug-in contour (10) at a conductor end (23) of an electrical conductor (20), in particular a stranded conductor, comprising the following steps: a. Forming, in particular press forming, the electrical conductor at the conductor end (23) to form a plug-in section (21) with at least one flat surface section (22a, 22b) at this conductor end (23), b. Providing a contact strip (30), wherein the contact strip (30) has several resilient contact lamellae (31) projecting from the contact strip (30), and c. Applying and connecting the contact strip (30) to the surface section (22a, 22b). A method for producing a plug-in contour (10) at a conductor end (23) of an electrical conductor (20), in particular a stranded conductor, comprising the following steps: a.a. Forming, in particular press forming of the electrical conductor at the conductor end (23) to form a plug-in section (21) with at least one flat surface section (22a, 22b) at this conductor end (23), b. Providing a contact strip (30), wherein the contact strip (30) has several resilient contact lamellae (31) projecting from the contact strip (30), and c. Applying and connecting the contact strip (30) to the surface section (22a, 22b). wherein at least one fastening element (50) for a correspondingly designed mating connector (60) is formed in the flat surface section (22a, 22b) and / or directly adjacent to the flat surface section (22a, 22b), in particular by forming and / or separating, and / or wherein the contact strip (30) is provided with the at least one fastening element (50) for the correspondingly designed mating connector (60).

3. Method according to claim 1 or 2, characterized in that the electrical conductor (20) is a busbar, in particular a solid busbar, and steps b) and c) are carried out directly on the surface of the busbar, omitting step a).

4. Method according to claim 1 or 2, characterized in that the electrical conductor (20) has a substantially round cross-sectional shape in the adjacent, non-formed area of ​​the conductor (20) adjoining the formed area.

5. Method according to claim 3 or 4, characterized in that a substantially cuboid-shaped conduit section is formed during the forming process.

6. Method according to one of the preceding claims 1, 2, 4 or 5, characterized in that the conductor end (23) is processed by means of compaction and in particular is formed into a shape in which the plug section (21) is formed with a flat top (22a) and a flat bottom (22b) substantially parallel thereto.

7. Method according to one of the preceding claims, characterized in that such a contact strip (30) is provided in which several parallel arranged contact lamellae (31 ) are provided and the edge contact lamella strip is applied to one of the surface sections (22a, 22b) at the end of the conductor (21 ) such that the parallel arranged contact lamellae (31 ) are oriented either along or transversely, in particular 90° transversely to the cable extension direction (L).

8. Method according to one of the preceding claims, characterized in that such a contact strip (30) is provided in which several parallel arranged contact lamellae (31 ) are provided and the edge contact lamella strip is applied to one of the surface sections (22a, 22b) at the conductor end (21 ) such that the parallel arranged contact lamellae (31 ) are oriented at an angle of 30° to 60°, preferably 45°, and / or 120° to 150°, preferably 135°, to the cable extension direction (L).

9. Electrical conductor (20), in particular an electrical stranded conductor (20) comprising a conductor end (23) with a plug contour (10) which forms a plug section (21) which has at least one flat surface section (22a, 22b) and at least one contact strip (30) applied directly to and connected with the surface section (22a, 22b), wherein the contact strip (30) has several (elastically) resilient contact lamellae (31) projecting from it.

10. Electrical conductor (20), in particular an electrical stranded conductor (20) having a conductor end (23) with a plug-in contour (10), which forming a plug-in section (21) which has at least one flat surface section (22a, 22b) and at least one contact strip (30) applied directly to and connected with the surface section (22a, 22b), wherein the contact strip (30) has several contact lamellae (31) projecting from it, in particular elastically resilient, wherein the plug-in section (21) of the cable end (23) has at least one fastening element (50) for a correspondingly designed mating plug (60), wherein in particular the at least one fastening element (50) is a latching element and / or a locking element. Electrical conductor (20) according to claim 10, wherein the at least one fastening element (50) is formed in the flat surface section (22a, 22b) and / or directly adjacent to the flat surface section (22a, 22b), wherein the fastening element (50) is in particular a recess, further in particular a groove-like recess.Electrical conductor (20) according to claim 10 or 11, wherein the at least one contact strip (30) comprises the at least one fastening element (51), wherein the at least one fastening element (50) is a spring element, a pin, a pin and / or a bayonet locking element. Electrical conductor (20) according to any one of claims 9 to 12, characterized in that the electrical conductor (20) has a substantially round cross-sectional shape in the adjacent, unformed area (24) of the conductor (20) adjoining the end-side plug-in section (21). Electrical conductor (20) according to any one of claims 9 to 13, characterized in that the contact strip (30) is connected at least to at least one fastening element (51) at its edge. a rib (32) has a rib at the edge area to which the several contact lamellae (31) are connected on one side and the other (opposite) end (34) of the contact lamellae (31) is formed as a free end.

15. Electrical conductor (20) according to one of claims 9 to 14, characterized in that two opposing surface sections (22a, 22b) are formed on the plug section (21) and a contact strip (30) connected to each surface section (22a, 22b) is applied and attached thereto.

16. Electrical conductor (20) according to one of claims 9 to 15, characterized in that at least one contact strip (30) with a projection (35) protrudes laterally and / or at the end face beyond the outer contour of the plug section (21), so that the respective projection (35) forms a contact and stop surface for interaction with a counter surface on a corresponding mating plug shaped accordingly for plugging together.

17. Electrical conductor (20) according to one of claims 9 to 16, characterized in that the conductor has a conductor sheath (26).

18. Electrical conductor (20) according to one of claims 9 to 17, manufactured according to the method according to one of claims 1 to 8.

19. Connector with a plug and a corresponding mating plug (60), wherein the plug is an electrical conductor (20), in particular an electrical stranded conductor (20), having a conductor end (23) which forms a plugging section (21) having at least one flat surface section (22a, 22b) and at least one contact strip applied directly to and connected with the surface section (22a, 22b). (30), wherein the contact strip (30) has several contact lamellae (31) projecting from it, in particular elastically resilient, wherein the plug-in section (21) of the cable end (23) has at least one fastening element (50) for the correspondingly designed mating connector (60), wherein in particular the at least one fastening element (50) is a latching element and / or a locking element. Connector according to claim 19, wherein the mating connector (60) is designed in two parts, wherein each part of the two-part mating connector (60) has a mutually complementary fixing means.

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