Connector terminal and method of manufactoring a connector terminal

Abstract

Connector terminal comprising a terminal body, wherein the terminal body has a contact body and a tab portion formed of a strip, wherein the contact body has a tubular form providing a cavity into which a plug-in connector is able to be plugged; and method of manufacturing a connector terminal having a terminal body, comprising the steps of providing a strip with a contact end and a tab end at two distal ends of the strip, forming a contact body and a tab portion of the strip, wherein the contact body is formed into a tubular form providing a cavity, into which a plug-in connector is able to be plugged.

Description

[0001] The application refers to a connector terminal comprising a terminal body, wherein the terminal body has a contact body and a tab portion formed of a strip, wherein the contact body has a tubular form providing a cavity into which a plug-in connector is able to be plugged; and further to a method of manufacturing a connector terminal having a terminal body, comprising the steps of providing a strip with a contact end and a tab end at two distal ends of the strip, forming a contact body and a tab portion of the strip, wherein the contact body is formed into a tubular form providing a cavity, into which a plug-in connector is able to be plugged.

[0002] Such a connector terminal comprises is formed of a strip-shaped metal sheet, which is bent such that the contact body forms an opening into which the plug-in connector can be inserted.

[0003] CN 219626933 U discloses a high-voltage connector terminal, a high-voltage connector cable assembly and a high-voltage connector. The high-voltage connector terminal comprises a terminal body and an elastic contact piece. The terminal body is an integrally formed piece, and the terminal body comprises a first connecting part which is provided with a hollow inner cavity and a second connection portion for direct electrical connection with a conductor core of the cable. The elastic contact element is inserted into the inner cavity of the first connecting part and is used for being electrically contacted with a matched terminal inserted into the inner cavity. The first connecting part is in the shape of a hollow cylinder, with a front end and a rear end opposite in the axial direction and two opposite sides in the circumferential direction. The two connecting parts include a first welding part connected to the side part on one side of the first connecting part and a second welding part connected to the side part on the other side of the first connecting part, so the first welding part and the second welding part are stacked on each other and are used for welding directly to the conductor core of the cable. Alternatively, the first welding part and the second welding part are plate-shaped and riveted together to prevent both sides of the first connecting part from being separated in the circumferential direction.

[0004] EP 3 378 128 B1 relates to a contact element comprising a contact body extended in a strip-shaped fashion, said contact body being bent such that the contact body forms an opening, into which a plug-in connector part can be inserted, wherein the contact body has a surface extended around the opening forming an inner wall of the opening. In the opening of the contact body, a contact lamella for electrically contacting a plug-in connector part inserted into the opening is arranged, and rests against the surface. The contact body is bent at one end in a bending direction around the plug-in direction towards the surface such that the end approaches the surface, wherein the contact body, at the end, has a flat area for bearing flat with the surface. The end, at the flat area, is materially bonded to the surface, in particular by welding, for example by laser welding.

[0005] With the connector terminals of the state of the art, opening of the contact body during mating and in mated condition with the plug-in connector part can occur, especially when subjected to vibrations, which results in a reduction of a contact pressure between the mated components and thus increases the contact resistance.

[0006] An objective can be to provide a connector terminal that provides a constant contact pressure and constant contact resistance.

[0007] The objective is achieved by a connector terminal according to claim 1 and by a method of manufacturing a connector terminal according to claim 13. Embodiments are subject to the respective dependent claims.

[0008] The connector terminal comprises a terminal body, wherein the terminal body has a contact body and a tab portion formed of a strip, wherein the contact body has a tubular form providing a cavity into which a plug-in connector is able to be plugged, and wherein the tab portion protrudes from the contact body. A contact end of the strip is bent to contact a locking portion of the strip, the contact end and the locking portion being joined together in a form-fit connection.

[0009] It is an advantage of the connector terminal that the form-fit connection between the contact end and the locking portion reliably prevents an opening of the contact body and the resulting decrease of the contact force between the contact body and the plug-in connector part. Further, the form-fit connection prevents a movement of the contact body in an axial direction during mating with the plug-in connector. The axial direction is defined by a centerline of the tubular contact body, which corresponds to a direction of insertion of the plug-in connector part. The connector terminal provides an advantageously compact design with the integrated form-fit connection.

[0010] The contact body can be obtained by bending the contact end of the strip to contact the locking portion. Advantageously, the form-fit connection features can be provided by stamping and / or coining operations on the strip before bending. The bending operation is finished by snap-fitting in the form-fit connection features and thus locking the form-fit connection. The form-fit connection can thus also be referred to as a snap-fit connection. The form-fit connection can join the contact end and the locking portion at least in regard of a relative movement of the contact end away from the locking portion in a radial and / or circumferential direction against a spring force of the bent contact body. The form-fit connection can further prevent a relative movement of the contact end and the locking portion in the axial direction. The contact end of the strip and a tab end of the strip are arranged at distal ends of the strip, the tab end of the strip forming an end of the tab portion.

[0011] Manufacturing the connector terminal by stamping and / or coining and bending operations, finishing in locking the form-fit connection of the contact end to the locking portion, advantageously enables to produce the connector terminal at one tool without the need of additional joining technologies like laser welding, resistance welding, or clinching, which renders the manufacturing cost effective.

[0012] According to an embodiment, the form-fit connection is provided by at least one cantilever arm arranged on the locking portion, the cantilever arm extending in a direction from the tab portion towards the contact end, wherein the cantilever arm engages the contact end.

[0013] The cantilever arm can have a hook portion at a distal arm end, and the contact end can have a corresponding catch engaging the hook portion, the catch and the hook portion being interlocked. The catch can be provided as one of a notch, a punch hole, a groove and an indentation at the contact end.

[0014] According to a further embodiment, the at least one cantilever arm has a chamfered edge at a distal arm end and the contact end has a correspondingly chamfered surface engaging the chamfered edge, the chamfered surface and the chamfered edge being frictionally connected at their respective contact surfaces. The chamfered surface can be provided at one of a notch, a punch hole, a groove and an indentation at the contact end.

[0015] According to a further embodiment, two chamfered surfaces and two chamfered edges can be provided, which can be interlocked pairwise, the chamfered surfaces and the chamfered edges being arranged at two distal edges of the contact end and the locking portion, respectively, in regard of the axial direction. Alternatively, one chamfered surface and one chamfered edge can be provided, which can be interlocked, the chamfered surface and the chamfered edge being arranged at a midpoint between the two distal edges of the contact end and the locking portion, respectively, in regard of the axial direction. The person skilled in the art is aware that more than two chamfered surfaces and two chamfered edges can be provided, and that a single chamfered surfaces and a single chamfered edge need not necessarily be arranged at the midpoint.

[0016] According to a further embodiment, the form-fit connection is provided by at least one protrusion extending from the contact end and at least one aperture on the locking portion, wherein the protrusion engages the aperture.

[0017] The protrusion can have a protrusion hook portion and the aperture can have an aperture catch engaging the protrusion hook portion, the aperture catch and the protrusion hook portion being interlocked.

[0018] According to a further embodiment, the protrusion has a chamfered protrusion surface and the aperture has an chamfered aperture edge engaging the chamfered protrusion surface, the chamfered aperture edge and the chamfered protrusion surface being frictionally connected at their respective contact surfaces.

[0019] A further aspect refers to a method of manufacturing a connector terminal having a terminal body, comprising the steps of providing a strip with a contact end and a tab end at two distal ends of the strip, and forming a contact body and a tab portion of the strip, wherein the contact body is formed into a tubular form providing a cavity, into which a plug-in connector is able to be plugged, by bending the contact end of the strip to contact a locking portion of the strip, and joining the contact end and the locking portion together in a form-fit connection.

[0020] The locking portion is arranged between the contact end and a tab end.

[0021] According to an embodiment, the method further comprises the steps: forming at least one cantilever arm on the locking portion, the cantilever arm extending in a direction from the tab portion towards the contact end, and engaging the cantilever arm with the contact end.

[0022] According to an embodiment, the method further comprises the steps: forming at least one protrusion extending from the contact end, forming at least one aperture on the locking portion, and engaging the protrusion with the aperture.

[0023] Advantageously, the cantilever arm, the protrusion, and the aperture can be manufactured in a cost effective process by stamping and / or coining.

[0024] Further features and advantages of the connector terminal and the method of manufacturing a connector terminal are further illustrated below with reference to exemplary embodiments shown in the accompanying drawings. In the Figures Figure 1 shows a connector terminal according to a first embodiment in a perspective view; Figure 2 shows the connector terminal of Figure 1 mated with a plug-in connector in a perspective view; Figure 3 shows the connector terminal of Figure 1 in detail in a perspective view; Figure 4 shows the connector terminal of Figure 1 in detail in a sectional view; Figure 5 shows the connector terminal according to a second embodiment in a perspective view; Figure 6 shows the connector terminal of Figure 5 in a side view; Figure 7 shows the connector terminal according to a third embodiment in a perspective view; Figure 8 shows the connector terminal of Figure 7 in another perspective view; Figure 9 shows the connector terminal of Figure 7 in detail in a sectional view; Figure 10 shows the connector terminal according to a fourth embodiment in a perspective view; Figure 11 shows the connector terminal of Figure 10 in another perspective view; Figure 12 shows the connector terminal of Figure 10 in detail in a sectional view; Figure 13 shows the connector terminal according to a fifth embodiment in a perspective view; Figure 14 shows the connector terminal of Figure 13 in detail in a sectional view.

[0025] In Figure 1, a connector terminal according to a first embodiment is illustrated in a perspective view. The connector terminal comprises a terminal body 10, wherein the terminal body 10 has a contact body 12 and a tab portion 16, both of which are formed of a strip 18. The contact body 12 has a tubular form providing a cavity 14. A contact spring 24 is form-fittingly inserted into the cavity 14 to improve electric contact between the contact body 12 and a plug-in connector, which is not depicted. The contact body 12 is formed into the tubular form by bending a contact end 22 of the strip 18 such that it contacts a locking portion 20 of the strip 18. The contact end 22 and the locking portion 20 are joined together in a form-fit connection. The form-fit connection joins the contact end 22 and the locking portion 20 at least in regard of a relative movement of the contact end 22 away from the locking portion 20 in a circumferential direction, the circumferential direction being defined by the tubular form of the contact body 12. The contact end 22 of the strip 18 and a tab end 21 of the strip 18 are arranged at distal ends of the strip 18, the tab end 21 of the strip 18 forming an end of the tab portion 16.

[0026] In Figure 2, the connector terminal of Figure 1 mated with a plug-in connector 36 is illustrated in a perspective view. The plug-in connector 36 is inserted into the cavity 14 of the contact body 12. The tubular form of the contact body 12 defines a central axis A, which defines axial, radial and circumferential directions. The axial direction corresponds with an insertion direction of the plug-in connector 36. The tab portion 16 protruding from the contact body 12 is connected to a wire terminal 37, for example by welding or soldering.

[0027] In Figure 3, the connector terminal of Figure 1 is shown in detail in a perspective view. Figure 4 shows the connector terminal of Figure 1 in detail in a sectional view. The Figures 3 and 4 will be described together. The tab portion 16 protrudes from the contact body 12 in a generally radial direction and comprises an offset 29. The form-fit connection is provided by at least one cantilever arm 23 arranged on the locking portion 20, the cantilever arm 23 extending in a direction from the tab portion 16 towards the contact end 22, wherein the cantilever arm 23 engages the contact end 22. The cantilever arm 23 has a hook portion 25 at a distal arm end and the contact end 22 has a corresponding catch 26 engaging the hook portion 25, the catch 26 and the hook portion 25 being interlocked. In the depicted embodiment, the catch 26 is provided as a recess or short groove but can as well be realized as a notch or a punch hole, an axially longer or continuous groove or an indentation at the contact end 22. The cantilever arm 23 with the hook portion 25 and the catch 26 on the contact end 22 can be formed by stamping and / or coining. When the contact body 12 is formed into the tubular form by bending the contact end 22 of the strip 18 to contact the locking portion 20 of the strip 18, the contact end 22 and the locking portion 20 are joined by engaging the cantilever arm 23 with the contact end 22.

[0028] In Figure 5, the connector terminal according to a second embodiment is illustrated in a perspective view. Figure 6 shows the connector terminal of Figure 5 in a side view. The Figures 5 and 6 will be described together. The second embodiment differs from the first embodiment in regard of the form-fit connection, which will thus be described. The form-fit connection is provided by two cantilever arms 23 arranged on the locking portion 20, the cantilever arms 23 each having a chamfered edge 27 at a distal arm end and the contact end 22 having a correspondingly chamfered surfaces 28 engaging the chamfered edges 27. The chamfered surfaces 28 and the chamfered edges 27 are frictionally connected at their respective contact surfaces. The two chamfered surfaces 28 and the two chamfered edges 27 are interlocked pairwise, the chamfered surfaces 28 and the chamfered edges 27 being arranged at two distal edges of the contact end 22 and the locking portion 20, respectively, in regard of the axial direction. In the depicted embodiment, the chamfered surfaces 28 are provided as recesses or short grooves but can as well be realized as notches or punch holes, indentations, or as axially longer grooves or one continuous groove at the contact end 22.

[0029] In Figure 7, the connector terminal according to a third embodiment is shown in a perspective view. Figure 8 shows the connector terminal of Figure 7 in another perspective view, in which the inside of the cavity 14 is visible. Figure 9 shows the connector terminal of Figure 7 in detail in a sectional view. The Figures 7-9 will be described together. The third embodiment differs from the first embodiment in regard of the form-fit connection, which will thus be described. The form-fit connection is provided by one cantilever arm 23 arranged on the locking portion 20, having a chamfered edge 27 at a distal arm end. The contact end 22 has a correspondingly chamfered surface 28 engaging the chamfered edge 27, the chamfered surface 28 and the chamfered edge 27 being frictionally connected at their respective contact surfaces. She single chamfered surface 28 and the chamfered edge 27 are interlocked, the chamfered surface 28 and the chamfered edge 27 being arranged at a midpoint between two distal edges of the contact end 22 and the locking portion 20, respectively, in regard of the axial direction. In the depicted embodiment, the chamfered surface 28 is provided at a recess 38 or short groove but can as well be realized as a notch or punch hole, indentation, or as an axially longer or continuous groove at the contact end 22.

[0030] In Figure 10, the connector terminal according to a fourth embodiment is shown in a perspective view. Figure 11 depicts the connector terminal of Figure 10 in another perspective view and Figure 12 shows the connector terminal of Figure 10 in detail in a sectional view. The Figures 10-12 will be described together. The tab portion 16 protrudes from the contact body 12 in a generally radial direction without any offset. The fourth embodiment further differs from the first embodiment in regard of the form-fit connection, which will thus be described. The form-fit connection is provided by a protrusion 30 extending from the contact end 22 and at least one aperture 31 formed on the locking portion 20, wherein the protrusion 30 engages the aperture 31. The protrusion 30 has a protrusion hook portion 32 and the aperture 31 has an aperture catch 33 engaging the protrusion hook portion 32, the aperture catch 33 and the protrusion hook portion 32 being interlocked. The protrusion 30 extending from the contact end 22 and the aperture 31 can be formed by stamping and / or coining. When the contact body 12 is formed into the tubular form by bending the contact end 22 of the strip 18 to contact the locking portion 20 of the strip 18, the contact end 22 and the locking portion 20 are joined by engaging the protrusion 30 with the aperture 31.

[0031] In Figure 13, the connector terminal according to a fifth embodiment is illustrated in a perspective view. Figure 14 shows the connector terminal of Figure 13 in detail in a sectional view. The Figures 13 and 14 will be described together. The fifth embodiment differs from the fourth embodiment in regard of the form-fit connection, which will thus be described. The form-fit connection is provided by the protrusion 30 extending from the contact end 22 and the aperture 31 formed on the locking portion 20, the protrusion 30 engaging the aperture 31. The protrusion 30 has a chamfered protrusion surface 34 and the aperture 31 has a chamfered aperture edge 35 engaging the chamfered protrusion surface 34, the chamfered aperture edge 35 and the chamfered protrusion surface 34 being frictionally connected at their respective contact surfaces.Reference Numerals

[0032] 10terminal body 12contact body 14cavity 16tab portion 18strip 20locking portion 21tab end 22contact end 23cantilever arm 24contact spring 25hook 26catch 27chamfered edge 28chamfered surface 29offset 30protrusion 31aperture 32protrusion hook portion 33aperture catch 34chamfered protrusion surface 35chamfered aperture edge 36plug-in connector 37wire terminal 38recess Acentral axis

Claims

1. Connector terminal comprising a terminal body (10), wherein the terminal body (10) has a contact body (12) and a tab portion (16) formed of a strip (18), wherein the contact body (12) has a tubular form providing a cavity (14) into which a plug-in connector is able to be plugged, and wherein the tab portion (16) protrudes from the contact body (12), a contact end (22) of the strip (18) being bent to contact a locking portion (20) of the strip (18), the contact end (22) and the locking portion (20) being joined together in a form-fit connection.

2. Connector terminal according to claim 1, characterized in that the form-fit connection joins the contact end (22) and the locking portion (20) at least in regard of a relative movement of the contact end (22) away from the locking portion (20) in a circumferential and / or radial direction.

3. Connector terminal according to any one of claims 1 or 2, characterized in that the form-fit connection is provided by at least one cantilever arm (23) arranged on the locking portion (20), the cantilever arm extending in a direction from the tab portion (16) towards the contact end (22), wherein the cantilever arm (23) engages the contact end (22).

4. Connector terminal according to claim 3, characterized in that the cantilever arm (23) has a hook portion (25) at a distal arm end and the contact end (22) has a corresponding catch (26) engaging the hook portion (25), the catch (26) and the hook portion (25) being interlocked.

5. Connector terminal according to claim 4, characterized in that the catch (26) is provided as one of a notch, a punch hole, a groove and an indentation at the contact end (22).

6. Connector terminal according to claim 3, characterized in that the at least one cantilever arm (23) has a chamfered edge (27) at a distal arm end and the contact end (22) has a correspondingly chamfered surface (28) engaging the chamfered edge (27), the chamfered surface (28) and the chamfered edge (27) being frictionally connected at their respective contact surfaces.

7. Connector terminal according to claim 6, characterized in that the chamfered surface (28) is provided at one of a notch, a punch hole, a groove and an indentation at the contact end (22).

8. Connector terminal according to claim 6, characterized in that two cantilever arms (23) are provided with two chamfered surfaces (28) and two chamfered edges (27) interlocked pairwise, the two cantilever arms (23) being arranged at two distal edges of the contact end (22) and the locking portion (20), respectively, in regard of an axial direction.

9. Connector terminal according to claim 6, characterized in that one chamfered surface (28) and one chamfered edge (27) are interlocked, the chamfered surface (28) and the chamfered edge (27) being arranged at a midpoint between two distal edges of the contact end (22) and the locking portion (20), respectively, in regard of an axial direction.

10. Connector terminal according to any one of claims 1 or 2, characterized in that the form-fit connection is provided by at least one protrusion (30) extending from the contact end (22) and at least one aperture (31) on the locking portion (20), wherein the protrusion (30) engages the aperture (31).

11. Connector terminal according to claim 10, characterized in that the protrusion has a protrusion hook portion (32) and the aperture (31) has an aperture catch (33) engaging the protrusion hook portion (32), the aperture catch (33) and the protrusion hook portion (32) being interlocked.

12. Connector terminal according to claim 10, characterized in that the protrusion (30) has a chamfered protrusion surface (34) and the aperture (31) has an chamfered aperture edge (35) engaging the chamfered protrusion surface (34), the chamfered aperture edge (35) and the chamfered protrusion surface (34) being frictionally connected at their respective contact surfaces.

13. Method of manufacturing a connector terminal having a terminal body (10), comprising the steps: - providing a strip (18) with a contact end (22) and a tab end (21) at two distal ends of the strip (18), - forming a contact body (12) and a tab portion (16) of the strip (18), wherein the contact body (12) is formed into a tubular form providing a cavity (14), into which a plug-in connector part is able to be plugged, by bending the contact end (22) of the strip (18) to contact a locking portion (20) of the strip (18), the locking portion (22) being arranged between the contact end (22) and a tab end (21), and - joining the contact end (22) and the locking portion (20) together in a form-fit connection.

14. Method according to claim 13, further comprising the steps: - forming at least one cantilever arm (23) on the locking portion (20), the cantilever arm extending in a direction from the tab portion (16) towards the contact end (22), and - engaging the cantilever arm (23) with the contact end (22).

15. Method according to claim 13, further comprising the steps: - forming at least one protrusion (30) extending from the contact end (22) and at least one aperture (31) on the locking portion (20), and - engaging the protrusion (30) with the aperture (31).

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