Cage for receiving a contact element

Abstract

The present invention relates to a cage for receiving a contact element. A cage (3; 3') for receiving a contact element (2; 2') for an electrical plug connector (33) has a fixing region (9) for fixing the cage (3) to the contact element (2; 2') and a spring region (10) axially adjoining the fixing region (9) for contacting a contact spring arm (8; 8') of the contact element (2; 2') with a spring force. The cage (3; 3') also has a covering region (11) axially adjoining the spring region (10) for covering a plug-side end of the contact element (2; 2'). An opening (14) in which a lamella (15; 15') is arranged is formed in the spring region (10). Its first axial end (16) is connected to the fixing area (9) and its second axial end (17) is connected to the covering area (11).The lamella (15; 15') is rotated from the first axial end (16) and from the second axial end (17) relative to a longitudinal axis of the lamella (15; 15') by a torsion angle ϕR, ϕR' in such a way that the contact spring arm (8; 8') can be contacted by the spring force from a contact point (21) of the lamella (15; 15').

Description

FIELD OF THE INVENTION

[0001] The present invention relates to a cage for receiving a contact element.

[0002] The present invention also relates to a contacting device comprising a contact element and a cage through which the contact element extends at least in sections.

[0003] Finally, the present invention relates to an electrical connector comprising a contacting device and a connector housing through which the contacting device extends at least in sections and to which the contacting device is connected. TECHNICAL BACKGROUND

[0004] Electrical connectors, particularly electrical connectors for high-voltage applications, for example in electric or hybrid vehicles, have contact elements made of a material with high electrical conductivity. In high-voltage applications, copper is preferably used for this purpose. However, copper has the disadvantage of poor aging and temperature resistance. The elasticity or spring force of contact spring tabs or contact spring arms of a contact element, which contact a corresponding mating contact element, decreases over time due to material fatigue (relaxation) or at high temperatures, as typically occur in high-voltage connectors. In both cases, the electrical contact resistance between the contact element and the mating contact element deteriorates adversely and, in extreme cases, can result in contact loss.

[0005] To prevent this, EP 2 690 716 B1, for example, proposes inserting the contact element, at least in its contacting area, into a sleeve-shaped housing—also called a cage—in which a number of over-springs corresponding to the number of contact spring arms of the contact element is formed. If the housing with its over-springs is made of a material with lower material fatigue, which includes, for example, stainless steel, and each contact spring arm of the contact element is contacted by an associated over-spring of the housing, then in the event of material fatigue of the copper in the contact element, the constant spring force of the over-spring acts on the associated contact spring arm and prevents deterioration of the electrical contact between the contact spring arm and the mating contact element.

[0006] Such a contacting device consisting of a contact element and a cage essentially has the following technical disadvantages: Due to a relative movement between the individual contact spring arms and the associated oversprings during the plugging process of the contacting device with the mating contact element, friction occurs between the individual contact spring arms and the associated oversprings, which additionally increases the plugging force.

[0007] In addition, the oversprings that are attached to the cage on one side are more susceptible to damage, such as bending, during handling during assembly.

[0008] Both technical disadvantages need to be improved. DESCRIPTION OF THE INVENTION

[0009] Against this background, the present invention is based on the object of specifying a contacting device comprising a contact element and a cage, which is improved with regard to its mechanical and / or geometric properties.

[0010] According to the invention, this object is achieved by a cage having the features of patent claim 1. Accordingly, it is provided:

[0011] A cage for receiving a contact element comprising a fixing region for fixing the cage to the contact element, a spring region axially adjoining the fixing region for contacting a contact spring arm of the contact element with a spring force, and a covering region axially adjoining the spring region for covering a plug-in end of the contact element, wherein an opening is formed in the spring region, in which a lamella is arranged, the first axial end of which is connected to the fixing region and the second axial end of which is connected to the covering region, wherein the lamella is rotated by a torsion angle relative to a longitudinal axis of the lamella, starting from the first axial end and from the second axial end, in such a way that the contact spring arm can be contacted with the spring force from a contact point of the lamella.

[0012] The knowledge / idea underlying the present invention consists in providing a cage with at least one lamella which is connected to the cage at its two axial ends and, starting from its two axial ends, is rotated about its longitudinal axis in such a way that, on the one hand, the lamella of the cage contacts an associated contact spring arm of the contact element and, on the other hand, the rotation of the lamella builds up a spring force in the lamella which acts in a rotational manner to the longitudinal axis and exerts a contact pressure on the associated contact spring arm.

[0013] The connection of the two axial ends of the lamella to the cage allows only a rotational movement of the lamella around its longitudinal axis when the mating contact element is inserted into the contact element. The corresponding contact spring arm of the contact element, which is connected to the contact element at a single axial end, performs a rotational movement around an axis orthogonal to the longitudinal axis of the contact element and thus to the longitudinal axis of the cage during the insertion process. This axis runs in the transition between the contact spring arm and the remaining body of the contact element. Due to its connection to the cage on both sides, the lamella does not perform such a rotational movement around an axis orthogonal to the longitudinal axis of the cage.The relative movement between a lamella rotating about its longitudinal axis and a contact spring arm rotating about an axis orthogonal to it is significantly smaller than the relative movement between a cover spring and a contact spring arm according to the prior art, both of which rotate about a corresponding and mutually parallel axis. Thus, the friction associated with the relative movement between the lamella of the cage according to the invention and the corresponding contact spring arm is significantly reduced, thus advantageously enabling a significantly lower insertion force during the insertion process.

[0014] The bilateral connection of the lamella to the cage according to the invention achieves better integration of the lamella into the cage's installation space. The risk of the lamella protruding from the cage's installation space, as is the case with the free axial end of a spring attached to the cage on one side, and thus the risk of damage to the lamella during the assembly process, is thus significantly reduced or completely eliminated.

[0015] A cage or a cage element can represent a housing into which the contact element can be inserted, at least in sections. Thus, a cage is preferably sleeve-shaped to enclose the contact element, at least in sections. The advantageous technical functions of the cage are, in particular: to apply an additional long-term and temperature-stable spring force to the contact spring arms of the contact element in order to compensate for a decreasing spring force of the contact spring arms as a result of material fatigue, to protect the contact spring arms of the contact element as far as possible from damage, in particular during the assembly process, and to fix the contact element in a connector housing and thus to achieve axial positioning of the contact element in the connector housing.

[0016] The contact element thus preferably extends at least with its contacting area within the cage. The basic geometry of the cage is preferably adapted to the basic geometry of the contacting area of ​​the contact element: since the contacting area of ​​the contact element has at least one contact spring arm, each of which is elongated to generate sufficient spring force, not only the contact element but also the cage is elongated. If the contact element is designed as a rotationally symmetrical round contact with several contact spring arms arranged rotationally symmetrically to the longitudinal axis, the associated cage is also designed rotationally symmetrically to its longitudinal axis.If the contact spring arms of the contact element for contacting a flat mating contact element are arranged in a cuboid basic structure with a rectangular cross-sectional profile, the cage also has a cuboid basic structure with a rectangular cross-sectional profile.

[0017] Since the contact element and the associated mating contact element can preferably be plugged into one another in the longitudinal axial direction, the cage preferably has a front-end plug-in opening for plugging in the mating contact element. Since preferably only a longitudinal section of the contact element extends within the cage, a residual body of the contact element, preferably the connection region, which is designed, for example, as a crimping region, is led out of the cage. Thus, a front-end opening is preferably formed in the cage at each of its two axial ends. The cage consequently preferably has a sleeve-shaped geometry that encloses the contact element at least in the contacting region. As will be explained in more detail below, the mating contact element can also be plugged laterally into the contacting region of the contact element.Thus, in a longitudinal section on at least one side of the cage, in which at least the contacting area of ​​the contact element is arranged within the cage, a lateral plug-in opening for feeding the counter-contact element can be formed.

[0018] The cage is preferably made of a material with low fatigue strength, preferably stainless steel. The cage is preferably manufactured using a stamping and bending technique. However, it is also conceivable to manufacture the cage using machining or casting techniques.

[0019] In the elongated cage, a fixing region is formed such that the fixing region can be mechanically and stably connected to an associated fastening region of the contact element. For this purpose, the geometry of the fixing region of the cage preferably corresponds to the geometry of the fastening region of the contact element: for example, a sleeve-shaped fastening region of the contact element with a rectangular cross-sectional profile can extend into a likewise sleeve-shaped fixing region of the cage with a likewise rectangular cross-sectional profile. However, deviations from such geometric equality are also conceivable, provided that a mechanically stable fixation is thereby possible: for example, a fastening region of the contact element with a U-shaped cross-sectional profile can extend into a fixing region of the cage with a rectangular cross-sectional profile.

[0020] The fixation between the fixation area and the fastening area is preferably designed as a form-fitting connection. For example, at least one locking tab, which is punched out and bent over in the fixation area, is locked in a corresponding locking recess formed in the fastening area. In a less preferred embodiment, a form-fitting connection between the fixation area and the fastening area can also be realized via a further body, for example a clip, which is locked in corresponding locking recesses in the fixation area and the fastening area. In addition, a force-fitting connection between the cage and the contact element is also conceivable, in which, for example, a press fit is realized between the fixation area and the fastening area.Finally, a material connection between the cage and the contact element can also be realized, for example via one or more soldering or welding points between the fixing area and the fastening area.

[0021] The fixing area of ​​the cage is adjoined axially in the direction of the plug-in end of the cage by the spring area of ​​the cage, in which at least one lamella is formed for contacting an associated contact spring arm arranged opposite in the contact element.

[0022] The spring area of ​​the cage is adjoined axially in the direction of the mating end of the cage by the covering area of ​​the cage, which is designed to cover the mating end of the contact element.

[0023] The three regions of the cage—the fixing region, the spring region, and the concealing region—are preferably connected to one another as a single piece, particularly in the case of a cage realized as a stamped and bent part. In a less preferred embodiment, the three regions of the cage can also each be manufactured from a single piece and subsequently connected to one another using known techniques. Thus, each individual lamella of the spring region is preferably connected to the fixing region and the concealing region.

[0024] A lamella is understood here and below to be a preferably elongated design with a small thickness. The longitudinal extent is therefore typically a multiple of the lateral transverse extent. The small thickness and the width, which is many times smaller than the length, of the lamella allows for easy deformation of the lamella in a direction of rotation relative to the longitudinal axis of the lamella. Such a lamella of the cage, also referred to as a torsion lamella due to its torsion capability, is preloaded by the torsion and can transfer the spring force preloaded by the torsion as contact pressure to the contacting contact spring arm of the contact element.

[0025] Each individual lamella of the spring region is connected to the fixing region at one axial end, referred to here and below as the first axial end of the lamella, and to the concealing region at another axial end, referred to here and below as the second axial end of the lamella. Thus, each individual lamella extends in its longitudinal direction in the longitudinal direction of the cage and thus in the longitudinal direction of the contact element arranged at least in sections in the cage. In order to be able to perform a torsional movement unhindered, each individual lamella is preferably not connected to the cage at any lateral end or at any lateral edge.

[0026] Thus, each individual lamella is arranged in an opening in the cage, i.e., in a passage through the cage. A corresponding opening in the cage can be formed for each individual lamella. Alternatively, several adjacent lamellas can be arranged in a common opening. The lamellae formed on a side wall of a cuboid cage can, for example, be arranged in a common opening in the cage.

[0027] Each individual lamella contacts the corresponding contact spring arm of the contact element with a contact point located on the surface of the lamella.

[0028] The contact point is preferably located on an edge of the lamella that is closest to the associated contact spring arm or that is formed on the lamella in the direction of the contact spring arm. The contact point is located between the first and second ends of the lamella, preferably in the axial center between the first and second ends of the lamella. Alternatively, the contact point of the lamella can also be axially offset from the axial center of the lamella, as explained in more detail below.

[0029] The covering area of ​​the cage, which is designed to protect the plug-side end of the contacting area, i.e., the individual contact spring arms of the contact element, extends at least to the plug-side end of the contact element and preferably beyond the plug-side end of the contact element. In addition, a frontal protection for the contact element can also be provided at the covering area for further protection of the contact element.

[0030] Advantageous embodiments and further developments emerge from the further subclaims and from the description with reference to the figures of the drawing.

[0031] It is understood that the features mentioned above and those to be explained below can be used not only in the combination specified in each case, but also in other combinations or on their own, without departing from the scope of the present invention.

[0032] In a preferred embodiment of the invention, the contact point of the lamella can be formed in a lateral section of the lamella, which represents a lateral extension or a lateral offset of the lamella in a direction towards the associated contact spring arm. Such an extension or offset of the lamella can also be referred to as a contact tongue. Particularly in the case of a narrow lamella, the approach of the contact point of the lamella to the associated contact spring arm caused by the torsion of the lamella can be too short to establish contact between the contact point of the lamella and the associated contact spring arm. In the case of a narrow lamella, the formation of the lateral extension or lateral offset enables reliable contact of the contact spring arm through the contact point of the lamella.

[0033] In a further advantageous embodiment of the invention, each individual lamella can have a rounded edge at the contact point. In this way, abrasion of a coating on the surface of the contact element can be reduced or, ideally, prevented. The contact element has a coating made of a material with high electrical conductivity, preferably silver or gold, particularly in the contact area, in order to reduce the electrical contact resistance between the contact element and the mating contact element, which is important for high-voltage applications.

[0034] The torsion angle by which the individual lamella is maximally twisted or rotated relative to the longitudinal axis in the area of ​​the contact point can preferably be designed between 10° and 50°. If the torsion angle of the lamella in this range is less than 10°, sufficient spring force cannot be achieved in the lamella to reinforce the spring force of the contact spring arm. If a torsion angle of 50° is exceeded, too great a spring force acts from the lamella on the contact spring arm, and the required insertion force is too high. A better compromise between the achievable spring force in the lamella and the insertion force that occurs can be achieved by using a torsion angle that is particularly preferably between 18° and 30° and even more preferably between 21° and 24°.

[0035] As already explained, the cage according to the invention, in a preferred embodiment, can accommodate a flat contact element, i.e., a flat contact element designed as a coupler for mating with a flat mating contact element designed as a contact blade. In this preferred embodiment, the cage can have a cuboid basic geometry with a rectangular cross-sectional profile.

[0036] A lamella can be formed on one side of the cage, which contacts a single contact spring arm of the contact element with a spring force in order to fix a flat mating contact element between the single contact spring arm and the opposite side wall. Alternatively, symmetrically arranged lamellas, i.e., oppositely arranged lamellas, of at least one pair of lamellas can be formed on opposite sides of the cage. Finally, an asymmetrical design of lamellas on two opposite sides of the cage is also conceivable, for example, one lamella on one side and, laterally offset, two lamellas on the opposite side of the cage.

[0037] If the flat contact element has two pairs of oppositely extending contact spring arms in its contacting area, then in the case of identically designed contact spring arms, the coating on the mating contact element is subjected to double abrasion during each lateral insertion cycle of the flat mating contact element into the flat coupler contact element due to the contact spring arms being arranged one behind the other in the lateral direction. To prevent this double abrasion, the contact points of the two contact spring arms with the mating contact element can be axially offset from one another in a contacting plane in a longitudinal direction of the contact spring arms.

[0038] In order for the contact point of the lamella to preferably, as will be explained in more detail below, contact a contact surface of the contact spring arm, which in the plugged-in state of the contact element and the mating contact element is oriented parallel to the contact plane of the contact spring arm with the mating contact element, the axial position of the contact point of the lamella with the associated contact spring arm is to be aligned with the axial position of the contact point of the contact spring arm with the mating contact element: thus, in a further preferred embodiment of the cage according to the invention, the contact points of those lamellae which are formed on the same side of the spring region of the cage can each be formed offset from one another in an axial direction of the lamellae.

[0039] In particular, the contact point of a lamella which contacts an associated contact spring arm, the contact point of which to the mating contact element is formed axially closer to the fastening region of the contact element, can also be formed axially closer to the fixing region of the cage than the contact point of another lamella which contacts another associated contact spring arm, the contact point of which to the mating contact element is formed axially further to the fastening region of the contact element.

[0040] In another particularly advantageous embodiment of the invention, in the case of lamellae with axially offset contact points, the diagonally opposite lamellae of two parallel contact spring pairs can each be formed at the same axial position in the longitudinal extension of the lamellae. Thus, the contact points of the diagonally opposite lamellae can have the same axial distance from the fixing area.

[0041] In this way, it is advantageously possible to flexibly insert a flat contact element with two pairs of contact spring arms in the two possible orientations (i.e., orientations that are rotated by 180° to the longitudinal axis of the contact element) into the cage with lamellae, each with axially offset contact points, without having to provide a matching mechanical coding means on the cage and the associated contact element. The design of the lamellae of the cage on one side of the cage thus corresponds to the design of the lamellae of the cage on the opposite side of the cage (i.e., the view of the cage "from above" corresponds to the view of the cage "from below").

[0042] Preferably, the torsion angle of the slats whose contact point is each axially further away from the fixing region can be greater than the torsion angle of the slats whose contact point is each axially closer away from the fixing region.

[0043] Thus, the lamellae with a further axial distance of the associated contact point from the fixing area can exert a higher spring stiffness on the associated contact spring arm than the lamellae with a closer axial distance of the associated contact point from the fixing area. Since lamellae whose contact point is axially further away from the fixing area of ​​the cage contact a contact spring arm whose contact point with the counter element is axially further away from the fastening area of ​​the contact element and thus has a lower spring stiffness, this further preferred embodiment of the invention allows the total spring stiffness from the spring stiffness of the lamella and the spring stiffness of the associated contact spring arm to be the same for all lamella-contact spring arm pairs.Thus, the mating contact element can experience the same contact pressure from all contact spring arms and thus an equal electrical contact resistance can be achieved at all electrical transitions between the contact element and the mating contact element.

[0044] Due to the equal axial distance between the contact points of the two diagonally opposite lamellae and the fixing area of ​​the cage, the two diagonally opposite lamellae are consequently each twisted by an equal torsion angle.

[0045] In a further preferred embodiment of the invention, an axial plug-in opening for axially inserting and plugging a mating contact element into the contact element can be formed at a front end of the covering area. The cross-sectional profile of the axial plug-in opening can preferably be adapted to the cross-sectional profile of the mating contact element. To protect the contact spring arms at the front end of the cage, the cross section of the axial plug-in opening can be reduced compared to the cross section of the cage. In the case of a cage realized as a stamped and bent part, the frontal covering of the contact spring arms can be achieved, for example, by bending two side walls of the covering area of ​​the cage by 90°.Optionally, the lateral end of the front cover can also be bent by an angle of less than 90° against the plugging direction of the mating contact element in order to implement a catch funnel function in the front cover and thus avoid a sharp edge.

[0046] In order to enable lateral insertion of a flat mating contact element into the contact element in a plug-in direction orthogonal to the longitudinal axis of the contact element or in both plug-in directions orthogonal to the longitudinal axis of the contact element, a lateral plug-in opening can be formed at least at one lateral end of the spring region, preferably at both lateral ends of the spring region. The cross-sectional profile of the lateral plug-in opening can preferably be adapted to the cross-sectional profile of the mating contact element. The lateral plug-in opening can extend not only within the spring region of the cage, in which the contacting region of the contact element is preferably formed, but also beyond the concealment region to the plug-side end of the cage. In the latter case, the axial plug-in opening can merge into the at least one lateral plug-in opening.The at least one lateral plug-in opening is formed on a further side of the cage, which is different from the sides of the cage in which the slats are formed.

[0047] To provide lateral protection for the contact spring arms, the height of each lateral plug-in opening at the lateral ends of the cage can be reduced compared to the corresponding lateral height of the cage. In the case of a cage realized as a stamped and bent part, the lateral covering of the contact spring arms can be achieved, for example, by bending two edge zones of the cage in the area of ​​the lateral plug-in openings by 90°. Optionally, the lateral end of the lateral coverings can each be bent by an angle of less than 90° against the lateral plug-in direction of the mating contact element in order to implement a catch funnel function in each lateral covering and thus avoid sharp edges.

[0048] In addition to the technical functions mentioned, the cage also performs a guiding function for the counter contact element due to the formation of a frontal cover and the lateral cover.

[0049] The technical function of fastening the contact element via the cage into a connector housing can preferably be implemented in a form-fitting manner: for this purpose, a locking means, preferably a locking hook, a locking lug, or a locking tab, can be formed on the cage, which can be locked with a counter-locking means of the connector housing, preferably a locking recess. To achieve a high locking force, the locking means can preferably have an elongated extension directed in the longitudinal axis direction of the cage. In a particularly advantageous embodiment, the locking means is formed in an opening in the cage, in which at least one lamella is also arranged. In addition to a form-fitting fastening of the cage to the connector housing, a force-fitting fastening (e.g., press fit) or a material-to-material fastening (e.g., soldering, welding, gluing) is also conceivable.

[0050] To protect the slats from damage, lateral protective walls can be formed on the two lateral edges of the opening or openings, which, in the case of a cage realized as a stamped and bent part, can be realized, for example, as edge zones of the opening or openings of the cage that are bent laterally outwards.

[0051] The invention also covers a contacting device for contacting a mating contact element of an electrical mating connector. The contacting device comprises a contact element and a cage through which the contact element extends, at least in sections. The technical features, technical characteristics, and technical aspects explained so far with regard to the cage apply analogously to the contacting device according to the invention and all other technical aspects of the invention explained below.

[0052] The contact element has at least one fastening region, which is or can be connected to the fixing region of the cage, and a contacting region, which is axially adjacent to the fastening region, for electrically and mechanically contacting an associated mating contact element. The contacting region has at least one contact spring arm, which is connected to the fastening region, wherein the at least one contact spring arm is designed to contact the mating contact element. As already explained above, the contacting region can also have a plurality of contact spring arms. In the case of a flat contact element, there can preferably be two pairs of opposite contact spring arms, i.e. two contact spring arms arranged on both sides and symmetrically to the flat mating contact element.

[0053] Due to the pretension of the lamella caused by the rotation of the lamella around its longitudinal axis, the contact point of each lamella contacts the corresponding contact spring arm with a spring force. The spring force acting from the lamella on the corresponding contact spring arm leads to a pretension of the contact spring arm. When the contact element and the mating contact element are plugged in, the contact spring arm is additionally pretensioned by the mating contact element. The contact pressure acting from the contact spring arm on the mating contact element is thus the result of the spring force of the lamella and the spring force of the corresponding contact spring arm. The spring force of the contact spring arm is amplified by the spring force of the lamella.

[0054] A connection area of ​​the contact element can be axially connected to the fastening area, opposite the contact area, for electrically and mechanically connecting the contact element to an electrical conductor of an electrical line (i.e., an electrical cable) or a printed circuit board. The electrical connection can be made by means of a soldered or welded connection, or alternatively, by means of a positive or non-positive crimp connection.

[0055] In a preferred embodiment of the contacting device according to the invention, the contact point of the individual lamella can contact a contact surface of the associated contact spring arm, which is shaped such that when the contact spring arm contacts a contact surface of the mating contact element, the contact surface is oriented parallel to the contact surface. In this way, even if the contact point of the lamella shifts relative to the contact surface of the contact spring arm due to fluctuations in the manufacturing accuracy of the cage and its lamellae, the force transmission from the lamella to the contact spring arm, and thus the contact pressure from the contact spring arm to the mating contact element, advantageously remains invariant.

[0056] In a further preferred embodiment of the contacting device according to the invention, which is particularly suitable for flat contacting, the contact element can have two pairs of two opposing spring contact arms each. The contact points of the contact spring arms, which are configured to contact the same contact surface of the mating contact element, can be offset from one another in an axial direction of the contact spring arms.

[0057] In this way, as already explained, double abrasion of the coating on the mating contact element is prevented in one mating cycle of the contact element and the mating contact element.

[0058] The contact points of the individual contact spring arms can preferably each be formed on a lateral extension or a lateral bulge of the contact spring arm in the direction of the counter contact element.

[0059] In the case of a flat contact, in a further advantageous embodiment of the contacting device according to the invention, the contact points of the diagonally opposite spring contact arms, which are designed to contact the counter-contact element, can each be formed at the same axial distance from the fastening area.

[0060] This allows the relative positioning of the contact points of the individual contact spring arms of the contact element, each of which contacts the mating contact element, to be adjusted to the relative positioning of the contact points of the individual lamellae of the cage, each of which contacts a corresponding contact spring arm of the contact element. The contact pressure of the individual contact spring arms of the contact element on the mating contact element, each of which is subjected to an additional contact pressure by a corresponding lamella of the cage, can thus be adjusted to the same level.

[0061] The invention also covers an electrical connector which has a contacting device and a connector housing through which the contacting device extends at least in sections and to which the contacting device is connected.

[0062] The technical features, technical characteristics and technical aspects already mentioned for the contacting device apply analogously to the electrical connector.

[0063] Finally, the invention also covers an electrical connector comprising an electrical plug connector and an associated electrical mating connector with a mating contact element. The mating contact element of the electrical mating connector is electrically contactable with or electrically contacts the contact element of the contacting device integrated in the electrical connector.

[0064] The invention also relates to a contact element of an electrical connector, independent of claim 1, for contacting a mating contact element of an associated electrical mating connector. This contact element has a fastening region and a contacting region axially adjacent to the fastening region for contacting the mating contact element, wherein the contact element has two pairs of two opposing spring contact arms, each of which is connected to the fastening region, wherein contact points of contact spring arms, which are configured to contact an identical contact surface of the mating contact element, are offset from one another in an axial direction of the contact spring arms. The dependent claims and the features described in the description relate to advantageous embodiments and variants of this contact element.The applicant explicitly reserves the right to claim the contact element described here independently of patent claim 1 (preferably, in particular, independently of the "cage" and its features), optionally in combination with features of the contact element described in connection with the cage and illustrated together with the cage in the drawings. Furthermore, the applicant reserves the right to claim an electrical connector and an electrical plug connection comprising the contact element independent of patent claim 1, thus preferably also without the described cage.

[0065] The above embodiments and developments can be combined with one another as desired, where appropriate. Further possible embodiments, developments, and implementations of the invention also include combinations of features of the invention not explicitly mentioned above or described below with respect to the exemplary embodiments. In particular, those skilled in the art will also add individual aspects as improvements or additions to the respective basic form of the present invention. TABLE OF CONTENTS OF THE DRAWING

[0066] The present invention will be explained in more detail below with reference to the exemplary embodiments shown in the schematic figures of the drawing. In the drawings: Fig. 1A an isometric representation of a flat contacting device according to the invention in the unplugged state, Fig. 1B an isometric representation of a flat contacting device according to the invention in the plugged state, Fig. 2A a longitudinal sectional representation of a cage according to the invention for a flat contact element, Fig. 2B an isometric representation of a cage according to the invention for a flat contact element, Fig. 2C a top view of a cage according to the invention for a flat contact element, Fig. 2D a cross-sectional representation of a cage according to the invention for a flat contact element, Fig. 2E an enlarged representation of a section of the cross-sectional representation of a cage according to the invention for a flat contact element, Fig. 3 a longitudinal sectional representation of a flat contact element according to the invention, Fig. 4 a longitudinal sectional representation of a flat contacting device according to the invention, Fig.5 is an isometric view of a laterally plugged plug connection according to the invention for flat contacting, Fig. 6A is an isometric view of a round contact element, Fig. 6B is an isometric view of a cage according to the invention for a round contact element, Fig. 6C is an isometric view of a round contacting device according to the invention, Fig. 7A is a longitudinal section view of a plug connection according to the invention for front-side flat contacting in the unplugged state and Fig. 7B is a longitudinal section view of a plug connection according to the invention for front-side flat contacting in the plugged state.

[0067] The accompanying drawing figures are intended to provide a further understanding of embodiments of the invention. They illustrate embodiments and, in conjunction with the description, serve to explain principles and concepts of the invention. Other embodiments and many of the noted advantages will be apparent upon reference to the drawings. Elements of the drawings are not necessarily shown to scale relative to one another.

[0068] In the figures of the drawing, identical, functionally identical and acting elements, features and components are provided with the same reference symbols, unless otherwise stated.

[0069] In the following, the figures are described coherently and comprehensively. DESCRIPTION OF EMBODIMENTS

[0070] A contacting device 1 comprising a flat contact element 2 and an associated cage 3 is shown in Fig. 1A in the unplugged state and in Fig. 1B shown in the plugged-in state. The contact element 2 and the respective cage 3 are each made from a stamped and bent part.

[0071] The contact element 2 has, in its longitudinal extension along a longitudinal axis L 1 , a contacting area 4, a fastening area 5 axially adjoining the contacting area 4 and a connecting area 6 axially adjoining the fastening area 5. The connecting area 6 is designed, for example, as a crimping area with a first pair of crimping wings 7 1 for crimping with the electrical conductor of a cable (not shown) and a second pair of crimping wings 7 2 for crimping with the cable sheath of the cable. The contacting area 4 of the contact element 2 has, in the form of the Figuren 1A und 1B two pairs of oppositely arranged contact spring arms 8, each of which is connected at one axial end to the fastening area 5. A counter-contact element designed as a flat contact, ie as a contact blade, can be inserted between the two pairs of oppositely arranged contact spring arms 8 and can be electrically contacted by them.

[0072] The cage 3 has, in its longitudinal extension along a longitudinal axis L 2, a fixing region 9 which is fixed or can be fixed to the fastening region 5 of the contact element 2, a spring region 10 axially adjoining the fixing region 9 and a covering region 11 axially adjoining the spring region 10.

[0073] The fixation between the fastening area 5 and the fixing area 8 is carried out, for example, as shown in the Figuren 1A und 1B As shown, via at least one locking tab 12 formed on the cage 3, which is or can be locked in a form-fitting manner into a corresponding locking recess 13 formed in the contact element 2. Other form-fitting, force-fitting, or material-fitting connection variants between the fastening region 5 of the contact element 2 and the fixing region 8 of the cage 3 are alternatively possible.

[0074] In an opening 14 of the spring area 9, at least one lamella 15 is arranged, which in the plugged-in state of the contacting device 1 contacts an associated contact spring arm 8, as shown in particular in Fig. 4 is shown. The number of lamellae 15 of the cage 3 thus preferably corresponds to the number of contact spring arms 8 of the contact element 2. Each lamella 15 is connected at its first axial end 16 to the fixing region 9 and at its second axial end 17 to the covering region 11. A longitudinal axis of each lamella 15 extends parallel to the direction of the longitudinal axis L 2 of the cage 3. The individual lamella 15 is designed as a torsion lamella, i.e. each lamella 15 is, starting from its first axial end 15 and its second axial end 17, in the direction of an axial section 19 located between the first axial end 16 and the second axial end 17, relative to its longitudinal axis by a torsion angle ϕ R (see Fig. 2D ) is rotated. Due to the torsion of the lamella 15, the individual lamella 15 is preloaded in such a way that the spring force built up by the preload in the lamella 15 can exert sufficient contact pressure on the associated contacting contact spring arm 8. Only the torsion of the individual lamella 15 enables contact between the lamella 15 and the associated contact spring arm 8.

[0075] To improve the contacting of the contact spring arm 8 by the associated lamella 15, a lateral section 20 is formed on the lamella 15 in the axial section 19 of the lamella 15 in the direction of the associated contact spring arm 8, which is also referred to as a contact tongue and is designed either as a lateral extension or as a lateral offset of the lamella 15. In the area of ​​the lateral section 19 or the contact tongue, a contact point 21 of the lamella 15 is preferably provided (see Fig. 4 ) which realizes the contact with the contact spring arm 8. It is also conceivable that several contact points 21 in the lateral section 20 of the lamella 15 contact the associated contact spring arm 15.

[0076] The covering area 11 of the cage 3 covers the contact spring arms 8 of the contact element 1 in the axial and lateral directions to prevent damage to the contact spring arms 8 from the outside as far as possible. The contact spring arms 8 of the contact element 2 do not touch the covering area 11 of the cage 5 when the contacting device is plugged in (see Fig. 4 ) so as not to restrict the spring travel of the individual contact spring arms 8.

[0077] At the plug-side end 22 of the cage 3, an axial plug-in opening 23 is formed in the cage 3, through which a mating contact element can be axially inserted into the contacting device 1. In the area of ​​the spring area 10 and the covering area 11 of the cage 3, a lateral plug-in opening 25 is formed in two opposite side walls 24 of the cage 3, through which a mating contact element can be inserted into the contacting device 1 in one of two possible lateral plug-in directions (see Fig. 5 ). The two opposite side walls 24 of the cage 3, in each of which a lateral plug-in opening 25 is formed, are oriented orthogonally to the side walls 26 of the cuboid-shaped cage 3, in which the lamellae 15 are formed. The axial plug-in opening 23 and the two lateral plug-in openings 25 preferably merge into one another, as can be seen in particular from Fig. 1B emerges.

[0078] To secure the contacting device 1 in a connector housing, at least one fastening means 27, preferably two fastening means 27, is formed in the cage 3. The individual fastening means 27 is preferably implemented as a locking tab that has a longitudinal extension in the direction of the longitudinal axis L 2 in order to enable the greatest possible spring force or the greatest possible spring travel. The individual locking tab is formed in an opening 14 of the cage 3 parallel to the lamellae 15.

[0079] For the axial protection of the individual contact spring arms 8 of the contact element 2, the axial plug-in opening 23 at the plug-side end 22 of the cage 3 is limited by axial protection areas 28 of the cage 3, at the lateral end of which a catching funnel function is formed in the direction of the plug-in opening 23 (see Fig. 1A ). Equivalently, each lateral plug-in opening 25 is delimited by two lateral protective areas 29 of the cage 3 in order to laterally protect the individual contact spring arms 8 of the contact element 2. At the lateral ends of the lateral protective areas 29 of the cage figs 3 In the direction of the plug-in opening 25, a catching funnel function is also formed.

[0080] In the Fig. 2A bis 2E the cage 3 according to the invention for a flat contact element 2 is shown. A longitudinal section is shown Fig. 2A , an isometric representation is based on Fig. 2B , a side view is shown Fig. 2C and a cross-sectional view is shown Fig. 2D The contact points 21 in the twisted lateral sections 20 of lamellae 15, which are formed on the same side wall 26 of the cage 3, are preferably axially offset from one another in the direction of the longitudinal axis L 2 of the cage, as can be seen from Fig. 2A Particularly preferably, the contact points 21 in the twisted lateral sections 20 of diagonally opposite lamellae 15 each have an equal axial distance x 1 or x 2 to the fixing area 9 of the cage figs 3 on.

[0081] In the cross-sectional view of cage 3 in Fig. 2D The rotations of the individual lamellae 15 around their longitudinal axis are shown. Fig. 2D It can be seen that the torsion angle ϕ R , by which two diagonally opposite lamellae 15 are rotated, is slightly smaller than the torsion angle ϕ R ', by which two further diagonally opposite lamellae 15 are rotated. The two first-mentioned lamellae 15 therefore have a lower spring stiffness than the two last-mentioned lamellae 15 and each contact contact spring arms 8 with a higher spring stiffness than the two last-mentioned lamellae 15. The overall stiffness for each pair of lamellae 15 and contact spring arm 8 is therefore the same.

[0082] In the enlarged section of a slat 15 in Fig. 2E It can be seen that the contact point 21 of a lamella 15 with the associated contact spring arm 8 is formed on a rounded edge of the lamella 15.

[0083] In Fig. 3 1 shows a section of a contact element 2 according to the invention with the contacting area 4 and the axially adjoining fastening area 5. The contacting area 4 of the contact element 2 for contacting a flat mating contact element has two pairs of contact spring arms 8 arranged opposite one another. The contact points 30 of contact spring arms 8, which each contact the same contact surface of a flat mating contact element, each have a different axial distance y 1 and y 2 from the fastening area 5 of the contact element 2 in the direction of the longitudinal axis L 1. Particularly preferably, the contact points 30 of diagonally opposite contact spring arms 8 have an equal axial distance y 1 or y 2 from the fastening area 5.

[0084] In Fig. 4 A contacting device 1 comprising the contact element 2 and the cage 3 is shown in the plugged-in state. The contact point 21 of each lamella 15 contacts a contact surface KF (in Fig. 4 the dashed line) of the associated contact spring arm 8. This contact surface KF is shaped in such a way that, in the plugged-in state of the contacting device 1 with the flat mating contact element, it is oriented parallel to the associated contact surface of the flat mating contact element.

[0085] In Fig. 5 a lateral plugging of the contacting device 1 with a flat counter contact element 31 is shown.

[0086] In Fig. 6A A round contact element 2' is shown, the contacting area 4' of which has several contact spring arms 8' arranged in the circumferential direction of the contact element 2'. In the associated cage 3' in Fig. 6B a corresponding number of slats 15' is formed. Fig. 6C Finally, a contacting device 1' emerges with a round contact element 2' and an associated cage 3', whose lamellae 15' are twisted in such a way that they contact the associated contact spring arms 8' with a contact pressure.

[0087] An electrical plug connection 32 comprising an electrical connector 33 and an associated electrical mating connector 34 is in the unplugged state in Fig. 7A and when plugged in Fig. 7Bshown. The electrical connector 33 contains the contacting device 1 consisting of a contact element 2, which is fastened in an associated cage 3, which is fastened in a connector housing 35 via two fastening means 27 designed as locking tabs. The electrical mating connector 34 contains a mating contact element 36, which is designed as a flat contact element, which is also fastened in a mating connector housing 37 via fastening means designed as locking tabs. The connector housing 35 and the mating connector housing 37 can be fixed to one another, for example, via a locking connection consisting of a locking hook 38 of the connector housing 35 and an associated locking recess 39 of the mating connector housing 37.

[0088] Although the present invention has been fully described above using preferred embodiments, it is not limited thereto but can be modified in many ways.

Claims

1. Cage (3; 3') for receiving a contact element (2; 2') for an electrical plug connector (33), comprising a fixing region (9) for fixing the cage (3) to the contact element (2; 2'), a spring region (10) axially adjoining the fixing region (9) for contacting a contact spring arm (8; 8') of the contact element (2; 2') with a spring force, and a covering region (11) axially adjoining the spring region (10) for covering a plug-in end of the contact element (2; 2'), wherein an opening (14) is formed in the spring region (10), in which opening a lamella (15; 15') is arranged, the first axial end (16) of which is connected to the fixing region (9) and the second axial end (17) of which is connected to the covering region (11), the lamella (15; 15') starting from the first axial end (16) and from the second axial end (17) relative to a longitudinal axis of the lamella (15; 15') by a torsion angle ϕ R , ϕ R' is rotated such that the contact spring arm (8; 8') can be contacted by the spring force from a contact point (21) of the lamella (15; 15').

2. Cage (3; 3') according to claim 1, characterized by that the contact point (21) of the lamella (15; 15') is formed in a lateral section (20) of the lamella (15; 15') which represents a lateral extension or a lateral offset of the lamella (15; 15') in a direction towards the contact spring arm (8; 8').

3. Cage (3; 3') according to claim 1 or 2, characterized by that the lamella (15; 15') has a rounded edge at the contact point (21).

4. Cage (3; 3') according to one of claims 1 to 3, characterized by that the torsion angle Φ R , ϕ R ' is preferably between 10° and 50°, particularly preferably between 18° and 30° and most particularly preferably between 21° and 24°.

5. Cage (3; 3') according to one of claims 1 to 4, characterized by thatthe cage (3; 3') has a rectangular cross-sectional profile and at least one lamella (15; 15'), preferably two pairs of two opposing lamellae (15; 15'), is or are formed on two opposite sides of the spring region (10).

6. Cage (3; 3') according to claim 5, characterized by that the contact points (21) of lamellae (15; 15') formed on the same side of the spring region (10) are each offset from one another in an axial direction of the lamellae (15; 15').

7. Cage (3; 3') according to claim 5 or 6, characterized by that the contact points (21) on the diagonally opposite slats (15; 15') each have the same axial distance x1, x2 from the fixing area (9).

8. Cage (3; 3') according to one of claims 5 to 7, characterized by that the torsion angle ϕ R' of the lamellae (15; 15'), whose contact point (21) is each axially further away from the fixing area (9), greater than the torsion angle ϕ R of the lamellae (15; 15'), the contact point (21) of which is each axially closer to the fixing area (9).

9. Cage (3; 3') according to one of claims 1 to 8, characterized by that an axial plug-in opening (23) is formed at a front end (22) of the covering area (11).

10. Cage (3; 3') according to one of claims 1 to 9, characterized by that a lateral plug-in opening (25) is formed at at least one lateral end of the spring region (10), preferably at both lateral ends of the spring region (10).

11. Contacting device (1; 1') for contacting a mating contact element (36) of an electrical mating connector (34) comprising a contact element (2; 2') and a cage (3; 3') according to one of claims 1 to 10, through which the contact element (2; 2') extends at least in sections, wherein the contact element (2; 2') has a fastening region (5) which is connected to the fixing region (9) of the cage (3; 3'), and a contacting region (4) axially adjoining the fastening region (5), wherein the contacting region (4) has at least one contact spring arm (8; 8'), which is connected to the fastening region (5), wherein the at least one contact spring arm (8; 8') is each configured to contact the mating contact element (36), wherein the contact point (21) of the respective lamella (15; 15') in each case contacts the associated contact spring arm (8; 8') contacted with the spring force.

12. Contacting device (1; 1') according to claim 11, characterized by that the contact point (21) of the respective lamella (15; 15') has a contact surface K F of the associated contact spring arm (8; 8'), which is shaped in such a way that when the contact spring arm (8; 8') is contacted with a contact surface of the counter-contact element (36), the contact surface K F is oriented parallel to the contact surface.

13. Contacting device (1; 1') according to claim 12, characterized by that the contact element (2; 2') has two pairs of two opposing contact spring arms (8; 8'), wherein contact points (21) of the contact spring arms (8; 8'), which are designed to contact an identical contact surface of the mating contact element (36), are offset from one another in an axial direction of the contact spring arms (8; 8').

14. Contacting device (1; 1') according to claim 13, characterized by that the contact points (21) of the diagonally opposite contact spring arms (8; 8'), which are designed to contact the counter-contact element (36), are each formed at an equal axial distance y1, y2 from the fastening region (5).

15. Electrical connector (33) comprising a contacting device (1; 1') according to one of claims 11 to 14 and a connector housing (35) through which the contacting device (1; 1') extends at least in sections and to which the contacting device (1; 1') is connected.

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