Electrical contact element and electrical plug-in connector

Abstract

The invention relates to an electrical contact element (1) formed from a formed sheet metal workpiece (2) in a sleeve-like shape, comprising a butt edge (5) formed by a first end (3) and a second end (4) of the formed sheet metal workpiece (2). At least one tab (6) is formed along the butt edge (5) at the first end (3) of the formed sheet metal workpiece (2). The tab (6) covers an end section (7) of the second end (4) opposite the first end (3) of the formed sheet metal workpiece (2) along the butt edge (5) in a lateral direction with respect to a central axis (M) of the contact element (1), wherein at least one primary bending edge (8) of the tab (6), about which the tab (6) is laterally bent with its front, free end (9), extends at least substantially orthogonally to the butt edge (5).

Description

[0001] The invention relates to an electrical contact element formed from a formed sheet metal workpiece in a sleeve-like shape at least substantially, having a butt edge formed by a first end and a second end of the formed sheet metal workpiece, according to the preamble of claim 1.

[0002] The invention further relates to an electrical connector comprising at least one electrical contact element.

[0003] Various electrical connectors are known from electrical engineering. Electrical connectors are known to transmit electrical power and / or data signals to corresponding mating connectors. A connector or mating connector can be, in particular, a plug, a PCB connector, a panel-mount connector, a socket, a coupling, or an adapter. The terms "connector" and "mother connector" used within the scope of the invention are representative of all variants.

[0004] The production of electrical connectors often requires an economical manufacturing process, particularly to enable mass production with low unit costs. Against this backdrop, contact elements are frequently manufactured as stamped and bent parts, meaning they are typically stamped from a sheet metal workpiece and bent into the intended shape (for example, a sleeve shape).

[0005] To attach a contact element to another connector component, such as a surrounding housing part, contact elements often have locking tabs that are punched out of the sheet metal workpiece and bent over. Punching and bending such a locking tab naturally creates an opening in the contact element, which reduces its mechanical stability (especially in the case of a sleeve-shaped contact element, as this interrupts the stabilizing sleeve-shaped geometry). The opening in the contact element can also impair its electrical properties (for example, the shielding effect of a conductor contact element may be compromised).

[0006] In particular, if the punched-out locking tab is formed in the area of ​​a butt edge of two ends of the sleeve-shaped sheet metal workpiece, the mechanical

[0007] The stability of the contact element may be particularly compromised. Often, the locking tab itself is also mechanically weakened in this case, as it consists of two halves formed by the respective ends of the sheet metal workpiece.

[0008] In view of the known state of the art, the object of the present invention is to provide an electrical contact element with optimized mechanical and electrical properties, which is preferably also economically producible in mass production.

[0009] The present invention also aims to provide an electrical connector with an electrical contact element that has optimized mechanical and electrical properties and that is preferably also economically manufacturable in the context of mass production.

[0010] The problem is solved for the electrical contact element by the features listed in claim 1. With regard to the electrical connector, the problem is solved by the features of claim 15.

[0011] The dependent claims and the features described below relate to advantageous embodiments and variants of the invention.

[0012] The invention relates to an electrical contact element formed from a formed sheet metal workpiece or sheet metal element (i.e., a predominantly flat metal part) in a sleeve-like shape. The electrical contact element has a butt edge formed by a first end and a second end of the formed sheet metal workpiece.

[0013] The requirement that the sheet metal workpiece is at least substantially sleeve-shaped can be understood to mean that the contact element is essentially completely closed in the circumferential direction or in cross-section, at least in certain sections. However, one or more slots may remain in the axial and / or circumferential direction in the area of ​​the butt joint. Furthermore, recesses or openings may be provided in the sheet metal workpiece. It should also be noted that the ends bent towards each other in the area of ​​the butt joint do not necessarily have to be connected or touching. The two ends may also be spaced apart, as long as an approximately ring-shaped cross-section is present, at least in certain sections.

[0014] The contact element can be described as being at least substantially sleeve-shaped within the meaning of the invention, in particular, if the function of a sleeve (e.g. as protection, guidance or for receiving further connector or cable components) can be fulfilled even if geometric deviations from an ideal sleeve are present.

[0015] Preferably, the contact element has a geometry that at least resembles a sleeve, i.e., it may, for example, have an elongated, hollow, usually cylindrical or conical shape that serves to accommodate or enclose further connector or cable components.

[0016] The electrical contact element can have a round, elliptical, rectangular, polygonal or other cross-sectional shape.

[0017] In this context, the term "butt edge" refers specifically to the edge or surface where the two ends of the sheet metal workpiece meet in their formed state. The butt edge is thus created only by forming or joining the ends and is therefore formed jointly by both ends. That is to say, each end preferably has its own butt surface at its edge, with these adjoining or aligned edges (which, however, do not necessarily have to touch) forming the butt edge. Within the scope of the present invention, the term "butt edge" may optionally also refer to or include the joint or gap between the ends.

[0018] According to the invention, at least one tab is formed along the butt edge at at least the first end of the formed sheet metal workpiece.

[0019] The tab in question can be configured to perform any mechanical and / or electrical function for the contact element or within an electrical connector equipped with the contact element. Preferably, the tab is a locking tab with which the contact element can be locked or secured on or within another connector or cable component (in particular within a connector component surrounding the contact element, such as a contact element carrier or a connector housing, or on a dielectric inserted into the contact element).

[0020] The tab can alternatively or additionally be an electrical contact tab for contacting another electrically conductive connector or cable component or a mating contact element of a mating connector.

[0021] According to the invention, the tab covers an end section of the second end, opposite the first end of the formed sheet metal workpiece along the butt joint, in a lateral direction with respect to a central axis of the contact element (that is, the covering preferably occurs in a top view of the contact element directed towards the central axis). At least one primary bending edge of the tab, around which the tab is bent laterally with its front, free end, runs at least substantially orthogonal to the butt joint.

[0022] The fact that the primary bending edge of the tab runs at least substantially orthogonally to the butt joint edge can be understood to mean, in particular, a deviation of less than 45° from an orthogonal course, preferably less than 20°, and more preferably less than 5°. Most preferably, the primary bending edge of the tab runs orthogonally to the butt joint edge.

[0023] It is particularly preferred that the front, free end of the tab is bent laterally outwards, i.e., bent away from the central axis. The tab can thus protrude outwards from the outer casing of the contact element. The contact element can therefore, for example, be contained and fixed in another component (e.g., in a contact element carrier, in a dielectric, or in a connector housing) or electrically contact said component (e.g., a mating contact element or a separate outer conductor component).

[0024] In principle, the tab can also be bent towards the central axis. The tab can thus project inwards from the inner surface of the contact element. The contact element can therefore, for example, accommodate and fix another component on its inside (e.g., a dielectric, especially if the contact element is designed as an outer conductor contact element) and / or make electrical contact (e.g., a mating contact element, a separate spring cage for contacting a mating contact element, or an outer conductor of a cable).

[0025] The contact element can be any type of contact element (in particular, an inner or outer conductor contact element). The contact element can also be a single component of a multi-part contact element.

[0026] The tab is essentially described below as a single locking tab arranged on the outside of the electrical contact element, and the contact element as an outer conductor contact element, which, however, is not to be understood as limiting for the invention.

[0027] Because the tab formed at the first end of the sheet metal workpiece, in its formed state, at least partially covers the second end of the workpiece, an opening beneath the tab and its negative mechanical and electrical effects can be significantly reduced. In particular, the electrical properties of the contact element, such as the shielding effect of an external conductor contact element, can be improved as a result.

[0028] The tab can be designed to be elastic, at least in sections, for example to be reversibly movable during the assembly of the contact element in the connector and / or to provide sufficient contact pressure for robust electrical contacting or mechanical centering and / or fixing.

[0029] In an advantageous embodiment of the invention, it can therefore be provided in particular that the tab has an elastic spring section between its free end and the primary bending edge.

[0030] The elastic spring section is preferably elastic in the lateral direction with respect to the central axis of the electrical connector or electrical contact element, so that the free end of the tab is movable against an elastic restoring force in the direction towards or away from the central axis.

[0031] The elastic spring section of the tab, which preferably forms the foremost part of the tab, is preferably the functionally relevant part of the tab for its mechanical and / or electrical use in the electrical connector. The elastic spring section can therefore preferably be used for direct locking and / or contacting with a separate component. Due to its elasticity, the tab can snap into place with its front, free end during the assembly of the contact element, for example, behind an undercut or in a locking recess of a connector component.

[0032] In one embodiment of the invention, it may be provided that the tab has a connection section which runs between the primary bending edge and a base point of the tab which is connected to a lateral surface of the sheet metal workpiece.

[0033] The connection section in question is preferably a transition area of ​​the tab that connects the elastic spring section to the base of the tab. The base can form the transition between the tab and the remaining surface or the base body / sheet metal workpiece in the area of ​​the first end. The base is thus the area from which the tab originates.

[0034] It can preferably be provided that a substantial direction of extension of the connecting section runs perpendicular to a substantial direction of extension of the elastic spring section, preferably at least substantially orthogonally, and particularly preferably orthogonally. That is to say, in particular, a central axis of the tab can run perpendicularly between the base and the free end of the tab. The central axis of the tab can preferably be composed of two central axis segments running perpendicular to each other, wherein one central axis segment of the connecting section can preferably be oriented at least substantially orthogonally to the central axis segment of the spring section.

[0035] According to a further development of the invention, it can be provided that the base of the tab is spaced away from the buttress edge in the circumferential direction.

[0036] Preferably, the connection section extends at least partially in the circumferential direction from the base point through the sheet metal workpiece or within the shell of the sleeve-shaped contact element. It can therefore be provided, in particular, that the connection section is at least partially machined or punched out of the outer surface of the sheet metal workpiece in its unbent state.

[0037] The geometry of the tab can, in principle, be arbitrary within the scope of the invention. In particular, the length and width of the tab can be designed, taking into account the intended use, such that a good technical compromise is achieved between sufficient stiffness of the tab for secure fixing (for example, in a snap-in recess of an adjacent connector component) or for secure electrical contact (for example, of another connector component or a mating contact element), and also sufficient flexibility to prevent abrasion or other damage during the assembly process and also to reduce the required assembly force.

[0038] It can be provided that the tab extends completely over the entire length of the butt joint edge. However, according to a preferred embodiment of the invention, it can be provided that the tab is only formed along a partial section of the butt joint edge.

[0039] It should be mentioned here that, in principle, it is also possible to have several tabs along the butt joint – possibly even originating from both ends, for example, alternating between the first and second ends of the sheet metal workpiece. The invention is described below with only a single tab for the sake of clarity, and this should not be understood as a limitation.

[0040] In a further development of the invention, it can be provided that at least one secondary bending edge is formed in the connection section, around which the connection section is bent laterally, preferably pointing away from the central axis of the contact element, but optionally also towards the central axis depending on the application.

[0041] Particularly preferably, the tab in the connection section has a pair of bending edges consisting of two spaced-apart secondary bending edges, around which the connection section is bent laterally in opposite directions, so that (viewed in cross-section) the bending profile of the tab in the connection section is preferably at least substantially S-shaped. It can be provided, in particular, that the tab is first bent from a tangential direction of extension to a lateral direction of extension and then back again from the lateral direction of extension to the tangential direction of extension by using the two secondary bending edges.

[0042] In particular, the S-shaped bend can be used to offset the tab in a defined manner relative to the outer surface of the sheet metal workpiece or the contact element. Due to the S-shaped bend, the tab, or at least the connecting section of the tab, can advantageously rest tangentially on the outer surface of the electrical contact element (especially on the covered section of the second end), either on the inside or outside.

[0043] In a further development of the invention, it can be provided that the secondary bending edges of the pair of bending edges run at least substantially parallel to each other.

[0044] The secondary bending edges of the bending edge pair can preferably also run at least substantially parallel to the butt edge.

[0045] The secondary bending edges of the bending edge pair can preferably also run at least substantially orthogonal to the primary bending edge.

[0046] In principle, the primary and secondary bending edges can each be arranged at any angle to each other (less preferred). For example, it is also possible for the primary bending edge and at least one secondary bending edge to run at least substantially parallel to each other.

[0047] In an advantageous embodiment of the invention, it can be provided that the tab has an at least substantially L-shaped profile in a top view.

[0048] Preferably, a first end of the L-shaped tab can represent the front, free end of the tab (i.e., in particular the elastic spring section) and the second end of the L-shaped tab can form the base point via which the tab is connected to the sheet metal workpiece.

[0049] In principle, however, any shape of the tab can be provided, starting from the base point to the free end, for example a Z-shaped, S-shaped, zigzag-shaped or other shape.

[0050] In a further development of the invention, it can be provided that the second end of the formed sheet metal workpiece runs straight along the butt edge, so that the tab covers a section of the shell extending from the second end.

[0051] A straight profile of the second end of the formed sheet metal workpiece is understood to mean, in particular, a profile of the second end without significant projections and / or recesses in the circumferential direction. The end face of the second end is therefore preferably completely flat.

[0052] In an advantageous further development of the invention, it can also be provided that the second end of the formed sheet metal workpiece has a laterally projecting flag section that extends at least partially under the tab.

[0053] The second end and the first end can thus, for example, interlock at least partially, forming a toothed / galvanized or even puzzle-like structure. It may also be possible for the two ends to interlock behind each other to provide a positive fit in the circumferential direction (e.g., a dovetail joint), thereby preventing the formed, sleeve-shaped contact element from springing back.

[0054] In an advantageous embodiment of the invention, it can be provided that the tab with the connecting section rests at least partially directly on the covered end section of the second end of the formed sheet metal workpiece.

[0055] The connecting section can therefore be particularly advantageous for supporting the elastic spring section and better supporting the overall mechanical stability of the contact element.

[0056] In an advantageous embodiment of the invention, it can be provided in particular that the connecting section is attached to the end section of the second end of the formed sheet metal workpiece.

[0057] The fastening can, in principle, be implemented in any way. However, a material-bonded fastening (e.g., a welded, soldered, or adhesive bond) and / or a form-fit fastening (e.g., a snap-fit, locking, or clinch connection) is preferred.

[0058] It should be mentioned at this point that, alternatively, the connection section can also be spaced away from the outer surface of the contact element or the sheet metal workpiece, for example to increase the elasticity of the tab.

[0059] In a further development of the invention, it can be provided that the first end and the second end of the formed sheet metal workpiece are connected or fastened to each other at least section by section along the butt joint.

[0060] Securing the first end to the second end is not strictly necessary, but can be advantageous to prevent unwanted springing of the sleeve-shaped contact element at the impact edge and to increase mechanical stability.

[0061] Provided that the two ends are attached to or connected to each other, this can in principle be done by any fastening technique, whereby a material-bonded fastening technique (e.g. a welding, soldering or adhesive connection) and / or a form-fit fastening technique (e.g. a snap-fit, locking or clinch connection) may be preferred.

[0062] According to a further development of the invention, it can be provided that the front, free end of the tab is aligned towards a cable-side end of the contact element.

[0063] By orienting the front, free end of the tab towards the cable-side end of the contact element, it is advantageously possible, on the one hand, to mount the contact element starting from the cable-side end of a connector (which is generally preferred), and on the other hand, to provide particularly secure cable strain relief. In principle, however, the front, free end of the tab can be oriented in any direction.

[0064] In an advantageous embodiment of the invention, it can be provided that the front, free end of the tab has a chamfer.

[0065] This can simplify the joining or assembly of the electrical contact element into a surrounding component or the insertion of another component into the contact element.

[0066] To further facilitate the assembly of the contact element within the connector, at least one end of the contact element can optionally be provided with a mechanical coding feature (e.g., one or more projections) that corresponds to a suitable counter-coding feature (e.g., a recess or an opening) on ​​a mating part of the connector. This ensures that the contact element can only be installed in the electrical connector in the correct orientation or phase alignment.

[0067] The invention also relates to an electrical connector comprising at least one electrical contact element according to the preceding and following embodiments.

[0068] The electrical connector may be provided to have a contact element carrier and / or a connector housing for receiving the at least one contact element.

[0069] The contact element is preferably mounted inside the connector housing and / or contact element carrier. The tab can latch or lock the contact element inside the connector (e.g., inside the connector housing or contact element carrier).

[0070] The electrical connector may be designed to have a dielectric material mounted inside the contact element. The tab can snap or lock the dielectric material within the contact element.

[0071] As mentioned above, the tab of the contact element can also serve for electrical contacting within the connector (e.g. for electrical contacting an electrically conductive outer housing) or for contacting by a mating contact element of a corresponding mating connector.

[0072] The contact element can be an outer conductor contact element, an inner conductor contact element, or another contact element (or part of a multi-part contact element) of the connector. Preferably, the contact element is designed as an outer conductor contact element.

[0073] The electrical connector is not limited to a specific connector standard or application. The electrical contact element can be advantageously suited for straight or angled connectors. The invention can be used advantageously for cable connectors, printed circuit board connectors, housing connectors, or adapter plugs, among others. Due to the optimized electrical properties of the contact element, the invention is particularly suitable for connectors in high-frequency technology (e.g., coaxial connectors), although this is not to be understood as a limitation.

[0074] The invention also relates to a method for manufacturing an electrical contact element, comprising at least the following process steps (not necessarily to be carried out in the specified order): Providing a sheet metal workpiece; forming the sheet metal workpiece into a geometry that is at least substantially sleeve-shaped, such that a common butt edge is formed by a first end and a second end of the sheet metal workpiece; forming at least one tab at the first end of the sheet metal workpiece along the butt edge, such that the tab covers an end section of the second end opposite the first end of the formed sheet metal workpiece along the butt edge in a lateral direction with respect to a central axis of the contact element; bending a front, free end of the tab in a lateral direction about at least one primary bending edge that is at least substantially orthogonal to the butt edge.

[0075] Features described in connection with one of the objects of the invention, in particular the electrical contact element, the electrical connector, and the method for manufacturing the electrical contact element, can also be advantageously implemented for the other objects of the invention. Likewise, advantages mentioned in connection with one of the objects of the invention can also be understood as relating to the other objects of the invention.

[0076] It should also be noted that terms such as "comprehensive," "exhibiting," or "with" do not exclude other characteristics or steps. Furthermore, terms such as "a" or "the," which indicate a singular number of steps or characteristics, do not exclude a plurality of characteristics or steps—and vice versa.

[0077] In a purist embodiment of the invention, however, it may also be provided that the features introduced in the invention with the terms "comprising," "comprising," or "with" are exhaustively listed. Accordingly, one or more lists of features within the scope of the invention may be considered complete, for example, for each claim. The invention may, for instance, consist exclusively of the features mentioned in claim 1.

[0078] It should be noted that designations such as "first" or "second" etc. are primarily used for the purpose of distinguishing between the respective device or process features and are not necessarily intended to indicate that features are mutually dependent or related to each other.

[0079] Furthermore, it should be emphasized that the values ​​and parameters described herein include deviations or fluctuations of ±10% or less, preferably ±5% or less, more preferably ±1% or less, and most preferably ±0.1% or less of the respective named value or parameter, provided that such deviations are not excluded in the practical implementation of the invention. The specification of ranges by initial and final values ​​also includes all those values ​​and fractions that are encompassed by the respective named range, in particular the initial and final values ​​and a respective mean value.

[0080] Exemplary embodiments of the invention are described in more detail below with reference to the drawings.

[0081] The figures each show preferred embodiments in which individual features of the present invention are combined with one another. Features of an embodiment can also be implemented independently of the other features of the same embodiment and can therefore be readily combined by a person skilled in the art to form further meaningful combinations and subcombinations with features of other embodiments.

[0082] In the figures, functionally identical elements are provided with the same reference symbols.

[0083] They show schematically: Figure 1 shows a sheet metal workpiece for forming a sleeve-shaped contact element according to a first embodiment of the invention, in an unformed state; Figure 2 shows a top view of the sleeve-shaped contact element. Figure 1, in the formed state of the sheet metal workpiece; Figure 3 a perspective view of the sleeve-shaped contact element of Figure 1, in the formed state of the sheet metal workpiece; Figure 4 a perspective view of a sleeve-shaped contact element according to a second embodiment, in the formed state of the sheet metal workpiece; Figure 5 an electrical connector according to an embodiment, with the electrical contact element according to Figure 4 in a longitudinal section; Figure 6 a sheet metal workpiece for forming a sleeve-shaped contact element according to a third embodiment of the invention, in an unformed state; Figure 7 a top view of the sleeve-shaped contact element of the Figure 6, in the formed state of the sheet metal workpiece; Figure 8 a sheet metal workpiece for forming a sleeve-shaped contact element according to a fourth embodiment of the invention, in an unformed state; Figure 9 a top view of the sleeve-shaped contact element of the Figure 8 , in the formed state of the sheet metal workpiece; Figure 10 a sheet metal workpiece for forming a sleeve-shaped contact element according to a fifth embodiment of the invention, in an unformed state; Figure 11 a sheet metal workpiece for forming a sleeve-shaped contact element according to a sixth embodiment of the invention, in an unformed state; and Figure 12 a sheet metal workpiece for forming a sleeve-shaped contact element according to a seventh embodiment of the invention, in an unformed state.

[0084] In the Figures 1 to 3Figure 1 shows an exemplary first embodiment of an electrical contact element 1 according to the invention. The electrical contact element 1 is formed from a formed sheet metal workpiece 2, at least substantially in a sleeve shape. In Figure 1, the sheet metal workpiece is shown in its unformed state and in the Figures 2 and 3 shown in a transformed state. Figure 2 shows a top view in the direction of the central axis M of the contact element 1 and Figure 3 a perspective drawing.

[0085] Within the scope of the invention, the sheet metal workpiece 2 is formed such that a first end 3 and a second end 4 of the sheet metal workpiece 2 (see respective figures) Figure 1 ) a common buttress edge 5 is formed (cf. Figures 2 and 3Along said butt edge 5, a tab 6 is formed at the first end 3 of the formed sheet metal workpiece 2 (in principle, several tabs 6 can also be provided, optionally also tabs extending from the second end 4 of the sheet metal workpiece 2). For the sake of clarity, the figures show, by way of example, only a single tab 6 extending along a section of the butt edge 5, which, however, should not be understood as limiting the invention.

[0086] It is intended that tab 6 will have an end section 7 (see dashed and hatched lines in Figure 2 ) of the second end 4 opposite the first end 3 of the formed sheet metal workpiece 2 along the butt edge 5 in a lateral direction with respect to the central axis M of the contact element 1 (i.e. in a top view, as in Figure 2 (shown, covered).

[0087] Because the tab 6 at least partially covers the second end 4 of the sheet metal workpiece 2, the opening below the tab 6 can be advantageously closed or filled by the end section 7 of the second end 4, thus optimizing the electrical and mechanical properties of the contact element 1. The contact element 1 is therefore able to offer improved electrical and mechanical properties compared to the prior art.

[0088] The tab 6 has at least one primary bending edge 8, around which the tab 6 is bent laterally with its front, free end 9. In the exemplary embodiment, the primary bending edge 8 runs orthogonally to the butt edge 5.

[0089] In the exemplary embodiments, the tab 6 is bent outwards at its front, free end 9, i.e., bent away from the central axis M of the contact element 1. However, depending on the application, it may also be provided that the tab 6 is bent inwards and thus projects into the sleeve-shaped contact element 1.

[0090] A second embodiment of the contact element 1, similar to the first embodiment, is shown by way of example in Figure 4 The contact element 1 corresponds, at least substantially, to the first embodiment in the area of ​​the tab 6, but is otherwise geometrically and functionally more complex. It should be mentioned here that, in particular, the [details omitted] Figures 1 to 3 and 6 to 12 The contact elements 1 shown are only to be understood as examples and schematics, in order to illustrate the basic principle of the invention. The contact element 1 according to Figure 4It has a plug-in area 10 designed as a spring basket for a mating contact element (not shown) of a mating connector, as well as a cable-side foot area 11 for mounting in a contact element carrier or a connector housing 12. A specific installation situation of the contact element 1 of the Figure 4 in a connector housing 12 of an electrical connector 13 according to an embodiment of the invention, is exemplified in Figure 5 shown in a longitudinal section.

[0091] The electrical contact element 1, which in the exemplary embodiments is an external conductor contact element, is in Figure 5The connector housing 12 is secured by means of the tab 6. In this example, the tab 6 serves as a locking tab and is engaged behind an undercut 14 in the connector housing 12. Assembly can advantageously be carried out starting from the cable-side end 15 of the connector 13. For this purpose, the front, free end 9 of the tab 6 is aligned towards the cable-side end 15 of the contact element 1 or connector 13 and is able to spring back during assembly and be held in place by the undercut 14. Figure 5 to spring back into the final assembly position shown. To facilitate insertion of the contact element 1 into the connector housing 12, the tab 6 can optionally have a chamfer at its front, free end 9. Optionally, mechanical coding, etc., can also be provided for the contact element 1 to ensure that it can only be inserted into the connector housing 12 in a specific orientation.

[0092] For example, in Figure 5Within the contact element 1 according to the invention, a dielectric 16 is shown, and within the dielectric 16, an inner conductor contact element 17 is shown. The inner conductor contact element 17 and the contact element 1 according to the invention, which is designed as an outer conductor contact element, are each connected at the cable-side end 15 of the connector 13 to the corresponding inner conductor 18 and the outer conductor 19 of the cable 20, respectively. The specific installation situation is, of course, only exemplary and not limiting to the invention, since the invention can, in principle, be suitable for any type of connector (for example, also for angled connectors and non-coaxial connectors).In particular, the contact element 1 according to the invention can also be an inner conductor contact element or another contact element, for example a support sleeve or another electrically conductive component required within the connector 13.

[0093] The tab 6 has an elastic spring section 21 between its front, free end 9 and the primary bending edge 8. This section can preferably serve for locking and / or electrical contact with a separate component, such as the connector housing 12 of the electrical connector 13 mentioned above. Furthermore, the tab 6 has a connection section 22 that runs between the primary bending edge 8 and a base 23 of the tab 6 connected to the sheet metal workpiece 2. This base 23 is circumferentially U (see figure). Figure 3 ) in the exemplary embodiments of the Figures 1 to 11The connection section 22 is spaced apart from the butt edge 5, so that, starting from the first end 3, it extends at least partially in the circumferential direction U within the shell of the sleeve-shaped contact element 1. For this purpose, the connection section 22 was preferably machined or punched out at least partially from the outer surface 24 of the sheet metal workpiece 2 before it was bent during manufacturing.

[0094] Due to the position of the foot point 23 or its distance d from the impact edge 5 (see in particular Figure 1 The opening formed at the first end 3 can be specified. This will be exemplified in the following. Figures 6 and 7 The illustrated embodiment of a further electrical contact element 1 according to the present invention represents an alternative position of the base point 23 starting from the butt edge 5 (cf. the changed distance d from the butt edge 5 in Figure 6It should be noted that a certain opening or width may generally be required to provide sufficient space for the S-shaped bending profile of the tab 6, which will be described below. Furthermore, it should be noted that if the distance d of the base 23 from the butt edge 5 is reduced, the tab 6, when assembled, will be positioned increasingly off-center from the butt edge 5 in the circumferential direction U (see overview of the Figures 2 and 7 This offset may sometimes be unproblematic due to the application and can be taken into account by the person skilled in the art when designing the contact element 1.

[0095] In the connection section 22 of the tab 6, a pair of bending edges 25 can be formed from two spaced-apart, secondary bending edges 26 (see in particular Figure 1), around which the connecting section 22 is bent laterally in opposite directions, as can be seen particularly well from the Figure 3 This can be seen. In this way, a bending profile that is at least substantially S-shaped can preferably result, whereby the tab 6 with its connection section 22 is able to rest tangentially on the lateral surface 24 of the contact element 1. The secondary bending edges 26 of the bending edge pair 25 run in the exemplary embodiments of the Figures 1 to 11 each parallel to the butt edge 5 and also orthogonal to the primary bending edge 8. The tab 6 can therefore, in a top view, at least essentially run in an L-shape.

[0096] However, it should be mentioned here that an L-shaped profile of the tab 6 and, in particular, the aforementioned alignment of the bending edges 8, 26 with respect to each other is not absolutely necessary. For example, see the [reference to] in Figure 12Reference is made to the illustrated embodiment, in which the parallel alignment of all bending edges 8, 26 results in a z- or zigzag-shaped profile of the tab 6 in a top view. In principle, many other possibilities exist for realizing the tab 6 according to the invention.

[0097] It can be provided that the second end 4 of the formed sheet metal workpiece 2 runs straight along the butt edge 5, so that the tab 6 covers a shell or end section 7 extending from the second end 4, as already shown in Figure 2 described. It can therefore be provided, in particular, that the second end 4 has no projections or recesses in the circumferential direction, as is also the case in the exemplary embodiment of the Figures 6 and 7 is clearly visible.

[0098] However, it is also possible that the second end 4 of the formed sheet metal workpiece 2 has a laterally projecting flap section 27 which, in the formed state of the sheet metal workpiece 2, extends at least partially under the tab 6. In this way, the opening below the tab 6 can be closed even more effectively. The tab 6 can thus cover the laterally projecting flap section 27 of the second end 4, as shown, for example, in the embodiment of the Figures 8 and 9 depicted.

[0099] As can be seen in particular from the Figure 3This results in the tab 6 with the connecting section 22 resting at least partially directly on the covered end section 7 of the second end 4 of the formed sheet metal workpiece 2. The connecting section 22 can optionally also be attached to the covered end section 7 of the second end 4 of the formed sheet metal workpiece 2, in particular by a material bond and / or a form-fit connection. In this way, the mechanical stability of the contact element 1 can be further improved. An example of a solder point 28 of the tab 6 is shown in Figure 3 indicated by dashed lines. Optionally, it may also be provided that the first end 3 and the second end 4 of the formed sheet metal workpiece 2 are joined together at least partially along the butt joint 5 by a material-locking and / or form-locking connection.

[0100] Examples will be provided using the Figures 10 and 11 Two further variants of advantageous tabs 6 are compared, whereby in Figure 10The distance of the base point 23 from the first end 3 or from the butt edge 5 is dimensioned such that the entire tab 6 is arranged within the sheet metal workpiece 2 in the undeformed state. In contrast, the elastic spring section 21 of the tab 6, according to the embodiment shown in Figure 11, projects completely out of the first end 3 of the sheet metal workpiece 2. In the case of the Figure 10 The opening formed under the tab 6 can, in the transformed or completed state of the contact element 1, again be closed by means of a suitably suitable, laterally projecting flag section 27 of the second end 4, whereas the second end 4 in the case of the exemplary embodiment of the Figure 11 can run in a purely straight line. However, in the exemplary embodiment, it is also possible, optionally, to... Figure 11A flag section 27 is provided (shown in dashed lines) to also close the opening of the tab 6 in the area of ​​the connection section 22.

[0101] Based on the Figure 10 Furthermore, it should be illustrated by example that an undercut can optionally be provided between the first end 3 and the second end 4 of the sheet metal workpiece 2, so that by inserting the second end 4 into the opening below the tab 6, improved mechanical fixation of the first end 3 to the second end 4 can be provided, thereby preventing the sleeve-shaped contact element 1 from springing up in the area of ​​the butt joint 5. For example, the flag section in Figure 10 For this purpose, it must be shaped conically (shown with dashed lines) so that a dovetail joint with a corresponding course of the other or first end 3 (also indicated with dashed lines) can be provided.

[0102] As already mentioned, the invention offers many different possibilities for the geometric design of the contact element 1, its tab 6, and for covering the second end 4 of the sheet metal workpiece 2 in order to at least partially close the opening below the tab 6. The examples mentioned above are therefore not exhaustive or limiting, but merely illustrative of the invention.

Claims

1. Electrical contact element (1) formed from a formed sheet metal workpiece (2) in a sleeve-like form at least substantially, comprising a butt edge (5) formed by a first end (3) and a second end (4) of the formed sheet metal workpiece (2), wherein at least one tab (6) is formed along the butt edge (5) at the first end (3) of the formed sheet metal workpiece (2), characterized by the fact that the tab (6) covers an end section (7) of the second end (4) opposite the first end (3) of the formed sheet metal workpiece (2) along the butt edge (5) in a lateral direction with respect to a central axis (M) of the contact element (1), wherein at least one primary bending edge (8) of the tab (6), about which the tab (6) is bent laterally with its front, free end (9), runs at least substantially orthogonally to the butt edge (5).

2. Electrical contact element (1) according to claim 1, characterized by the fact thatthe tab (6) has an elastic spring section (21) between its free end (9) and the primary bending edge (8), preferably for locking and / or contacting with a separate component, and a connection section (22) which runs between the primary bending edge (8) and a base point (23) of the tab (6) which is connected to a lateral surface (24) of the sheet metal workpiece (2).

3. Electrical contact element (1) according to claim 2, characterized by the fact that the foot point (23) is spaced in the circumferential direction (U) from the buttress edge (5).

4. Electrical contact element (1) according to one of claims 1 to 3, characterized by the fact that the tab (6) is only formed along a section of the butt edge (5).

5. Electrical contact element (1) according to one of claims 2 to 4, characterized by the fact thatin the connection section (22) a pair of bending edges (25) is formed from two spaced-apart, secondary bending edges (26) around which the connection section (22) is bent laterally in opposite directions, so that preferably an at least substantially S-shaped bending profile results.

6. Electrical contact element (1) according to claim 5, characterized by the fact that the secondary bending edges (26) of the bending edge pair (25) run at least substantially parallel to the butt edge (5).

7. Electrical contact element (1) according to one of claims 1 to 6, characterized by the fact that the tab (6) is at least substantially L-shaped in a top view.

8. Electrical contact element (1) according to any one of claims 1 to 7, characterized by the fact that the second end (4) of the formed sheet metal workpiece (2) runs straight along the butt joint (5).

9. Electrical contact element (1) according to any one of claims 1 to 7, characterized by the fact thatthe second end (4) of the formed sheet metal workpiece (2) has a laterally projecting flag section (27) which extends at least partially under the tab (6).

10. Electrical contact element (1) according to one of claims 2 to 9, characterized by the fact that the tab (6) with the connecting section (22) rests at least partially directly on the covered end section (7) of the second end (4) of the formed sheet metal workpiece (2).

11. Electrical contact element (1) according to claim 10, characterized by the fact that the connecting section (22) is attached to the end section (7) of the second end (4) of the formed sheet metal workpiece (2), preferably by material joining and / or by form joining.

12. Electrical contact element (1) according to any one of claims 1 to 11, characterized by the fact thatthe first end (3) and the second end (4) of the formed sheet metal workpiece (2) are connected to each other at least partially by material interlocking and / or form interlocking along the butt joint (5).

13. Electrical contact element (1) according to any one of claims 1 to 12, characterized by the fact that the front, free end (9) of the tab (6) is aligned towards a cable-side end of the contact element (1).

14. Electrical contact element (1) according to any one of claims 1 to 13, characterized by the fact that the front, free end (9) of the tab (6) has a chamfer.

15. Electrical connector (13) comprising at least one electrical contact element (1) according to one of claims 1 to 14 and a contact element carrier and / or a connector housing (12) for receiving the at least one contact element (1).

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