CONTACT DEVICE, SYSTEM AND METHOD FOR PRODUCING SUCH A CONTACT DEVICE

Abstract

The present invention relates to a contact device (20), a system (10) and a method for producing such a contact device (20), in which the contact device (20) has a first contact element (100), in which the first contact element (100) has a first shoulder section.(135), a first contact section (125), a second contact section (130), and a first connecting section (120), wherein the first contact section (125) is formed so as to permit contact with a first pluggable contact receptacle (25) of the other contact device (21), wherein the first connecting section (120) electrically and mechanically connects the first contact section (125) to the second contact section (130), wherein the first contact section (125) and the first connecting section are formed at least partially in a first plane of material (145), wherein the first shoulder section (135) is formed at the level of the first connecting section (120) and extends transversely away from the first connecting section (120), wherein the first shoulder section (135) is bent so as to exit the first material plan (145).Figure for the abbreviation: Figure 4.

Description

Title of the invention: CONTACT DEVICE, SYSTEM AND PRODUCTION METHOD OF SUCH A CONTACT DEVICE

[0001] The present invention relates to a contact device, a system and a method for producing a contact device.

[0002] An electrical connector is known from document EP 1 341 270 Bl.

[0003] The object of the present invention is to provide an improved contact device, an improved system and an improved method for producing such a contact device.

[0004] The present object is achieved by means of a contact device for establishing contact with another contact device of a system. The contact device has a first contact element, wherein the first contact element has a first shoulder section, a first contact section, a second contact section and a first connection section, wherein the first contact section is formed in such a way as to enable contact to be established with a first plug-in contact receptacle of the other contact device, wherein the first connection section electrically and mechanically connects the first contact section to the second contact section, wherein the first contact section and the first connection section are formed at least partially in a first material plane,wherein the first shoulder section is formed at the first connecting section and extends transversely away from said first connecting section, wherein the first shoulder section is angled so as to exit the first material plane.

[0005] This configuration has the advantage that the contact element is manufactured particularly precisely and that warping or tilting of the first contact section in the associated plug-in contact receptacle of another contact device is avoided when applying a pressing force to the shoulder section. Furthermore, it is possible to dispense with additional means, in particular plastic housings, for applying the pressing force to the first shoulder section since the pressing tool can be placed directly on the first shoulder section. This makes the contact device particularly light and easy to manufacture.

[0006] Advantageous embodiments are specified in the dependent claims.

[0007] In another embodiment, the contact device has a second contact element arranged offset transversely to the first material plane. The second contact element has a second shoulder section and a second connection section which extends at least partially in a second material plane, wherein the second shoulder section is formed at the second connection section and extends transversely to the second connection section from the second connection section towards the first contact element, wherein the second shoulder section is bent so as to protrude from the second material plane.This results in both shoulder sections being freely accessible from one direction, in particular parallel to the first contact section, so that force application can be effected via all shoulder sections by means of one tool.

[0008] In another embodiment, the first shoulder section and the second shoulder section are arranged offset from each other in a direction parallel to the first material plane. Thus, a particularly large distance between the two shoulder sections is provided and contact between the two shoulder sections is avoided.

[0009] It is particularly advantageous if the first material plane and the second material plane are arranged side by side in a parallel and spaced manner.

[0010] In another embodiment, the first shoulder section is bent so as to emerge from the first material plane with a first curvature, preferably in an arc-shaped manner, particularly preferably along a circular path. This configuration has the advantage of avoiding material damage, in particular the formation of cracks, at the transition between the first connection section and the shoulder section. Brittle materials can thus also be used for the first contact element.

[0011] In another embodiment, the second shoulder section is curvedly formed with a second curvature, preferably in an arc shape, particularly preferably along a further circular path, wherein the first curvature is counter-rotating relative to the second curvature.

[0012] It is particularly advantageous that the first curvature is generated around a first curvature axis and that the second curvature is generated around a second curvature axis, wherein the first curvature axis is arranged offset from the second curvature axis along the first material plane.

[0013] In another embodiment, the first connection section has a first cutting surface and, on a side facing the second connection section, a first side surface, wherein the first cutting surface adjoins the first side surface and the first side surface is arranged in inclined manner relative to the first cutting surface, wherein the first shoulder section is formed at the first connection section between the first contact section and the first cutting surface, wherein the first shoulder section passes in front of the first side surface and projects relative to the first side surface. By arranging the first shoulder section between the cutting surface and the contact section, the first contact element can be manufactured in a particularly dimensionally stable manner.

[0014] In another embodiment, the second connecting section has a second cutting surface and a second side surface facing the first connecting section, wherein the second cutting surface adjoins the second side surface, wherein the second side surface is arranged parallel to the first side surface and opposite the first side surface, wherein the second shoulder section projects from the second side surface toward the first side surface.

[0015] In another embodiment, the contact device has a contact housing with a first contact receptacle and a housing end face, in which at least the second contact section of the first contact element engages in the first contact receptacle, in which the first cutting surface is oriented parallel to the housing end face.

[0016] In another embodiment, the first connection section has a first sub-region and a second sub-region adjoining the first sub-region, wherein preferably the second sub-region is oriented aligned with respect to the first contact section, wherein the first sub-region and the second sub-region are oriented inclined with respect to each other, wherein the first sub-region is arranged to adjoin the second contact section, wherein preferably the second contact section is arranged aligned with respect to the first sub-region, wherein the first sub-region, the second sub-region and the second contact section are formed to extend in the first material plane.This avoids accumulations of tolerances, particularly when bending individual sub-regions of the first contact element, so that the first contact element is particularly dimensionally stable.

[0017] In another embodiment, the first contact element has a third shoulder section, wherein the third shoulder section is formed at the first connection section on a side opposite the first shoulder section, wherein the third shoulder section extends transversely to the first connection section from the first connection section in the direction opposite that of the first section shoulder, wherein the third shoulder section is bent so as to protrude from the first material plane in the opposite direction to that of the first shoulder section. As a result, the pressing force can be applied to the first contact element from both sides via the first and third shoulder sections and a cant of the first contact element is avoided when it is pressed into the other contact device.

[0018] In another embodiment, the second contact element has a fourth shoulder section, wherein the fourth shoulder section is formed at the second connection section on a side opposite the second shoulder section, wherein the fourth shoulder section extends transversely to the second connection section from the second connection section in the direction opposite that of the second shoulder section and is bent so as to exit the second material plane in the direction opposite that of the second shoulder section. This avoids electrical and mechanical contact between the first shoulder section and the fourth shoulder section. It is thus possible to dispense with further insulating means, in particular contact housing inserts, for the electrical insulation of the first and second contact elements.

[0019] The object of the invention is also achieved by means of an improved system in that the system has a contact device and a further contact device, in which the contact device is formed as explained above. The further contact device can be arranged at an electrical connection device which can be formed as a printed circuit or an electrical rail system. The further contact device has at least one first plug-in contact receptacle, in which a first contact section of the first contact element engages in the first plug-in contact receptacle and the first contact section forms an electrical contact with the first plug-in contact receptacle.

[0020] The contact device can be manufactured according to a production method in a particularly easy and inexpensive manner and with high dimensional stability by cutting, preferably by stamping, the first connection section, the first shoulder section, the first contact section and the second contact section from a thin-walled material extending in the first material plane, in which the first shoulder section is bent so as to protrude from the first material plane while adjoining the first connection section.

[0021] This configuration has the advantage that the material of the first connection section remains unchanged and that microcracks that can occur in the material of the first connection section, for example during bending, are avoided. Furthermore, the material structures are not bent relative to each other and are therefore preserved compared to the rolling process used to produce the thin-walled material.

[0022] The present invention is explained in more detail below with the aid of figures:

[0023] [Fig-1] shows a perspective representation of a system with a circuit printed and a contact device according to a first embodiment;

[0024] [Fig.2] shows a sectional side view of a first contact element of the system shown in [Fig.l];

[0025] [Fig.3] shows a perspective view of a contact device of the system shown in Figures 1 and 2;

[0026] [Fig.4] shows a section A, marked in [Fig.3], of the contact device shown in [Fig.3];

[0027] [Fig.5] shows a sectional top view of the contact device shown in [Fig.l];

[0028] [Fig.6] shows a side view of a third contact element of the system shown in Figures 1 to 4;

[0029] [Fig.7] shows a flowchart of a production process of the system shown in Figures 1 to 7;

[0030] [Fig.8] shows a side view of the first contact element before and during a third process step;

[0031] [Fig.9] shows the section shown in [Fig.4] during a seventh process step;

[0032] [Fig. 10] shows a sectional top view of a development of the contact device shown in Figs. 1 to 9;

[0033] [Fig. 11] shows a top view of a contact device according to a second embodiment;

[0034] [Fig. 12] shows a top view of a contact device according to a third embodiment.

[0035] In the following figures and for better understanding, reference is made to a coordinate system. The coordinate system has an x-axis (longitudinal direction), a y-axis (transverse direction) and a z-axis (vertical direction). The coordinate system is designed as an example as an orthonormal system.

[0036] [Fig.l] shows a perspective representation of a system 10 with a contact device 20 according to a first embodiment.

[0037] The system 10 further has a further contact device 21 arranged at an electrical connection device 15. The electrical connection device 15 may be formed, for example, as a printed circuit or contact rail. The electrical connection device 15 may have a plurality of conductors electrical, not shown, for example conductive tracks or electrical conduction rails.

[0038] The electrical connection device 15 has a further contact device 21. The further contact device 21 has at least one first plug-in contact receptacle 25 and at least one second plug-in contact receptacle 30. In the present embodiment, the first and second plug-in contact receptacles 25, 30 are, for example, arranged side by side within a first row 35, wherein the first row 35 extends along a first straight line 36 parallel to the x-axis.

[0039] The number of first and second plug-in contact receptacles 25, 30 is not limited here. Thus, in [Fig. 1], the other contact device 21 has a plurality of first and second plug-in contact receptacles 25, 30 arranged side by side within the first row 35 and arranged, for example, alternately with respect to each other.

[0040] The first and second plug-in contact receptacles 25, 30 are designed as a through opening, in particular as a pin contact. The first and second plug-in contact receptacles 25, 30 can each be electrically connected to an electrical conductor of the electrical connection device 15. In the present embodiment, the first and second plug-in contact receptacles 25, 30 are designed, by way of example, in an identical manner.

[0041] Additionally, the further contact device 21 may have at least one third plug-in contact receptacle 40 and at least one fourth plug-in contact receptacle 45, in which the third and fourth plug-in contact receptacles 40, 45 are, for example, formed identically to the first and second plug-in contact receptacles 25, 30. The third and / or fourth plug-in contact receptacle 40, 45 may here be implemented as a pin contact.

[0042] In the present embodiment, the third plug-in contact receptacle 40 and the fourth plug-in contact receptacle 45 are arranged side by side in the x-direction, wherein the third and fourth plug-in contact receptacles 40, 45 are preferably arranged within a second row 50 which extends along a second straight line 51 parallel to the x-axis and thereby parallel to the first row 35. The third and fourth plug-in contact receptacles 40, 45 are also electrically connected respectively to an electrical conductor of the electrical connection device 15. The first and third plug-in contact receptacles 25, 40 are arranged by way of example in a first common yz-plane 52 and the second and fourth plug-in contact receptacles 30, 45 are arranged in a second plan yz 53 common.

[0043] The contact device 20 has a contact housing 55. The contact housing 55 may, for example, have an electrically non-conductive material, in particular a plastic material. The contact housing 55 has, for example, a lower face 60, in which the lower face 60 rests, for example, on an upper face 65 of the electrical connection device 15, for example as shown in [Fig. 1], of the printed circuit. The upper face 65 is formed in a substantially planar manner and may extend in an xy plane. Additionally, the contact housing 55 may be connected in a form-fitting manner to the electrical connection device 15, for example by means of a locking device (not shown). Alternatively, gluing or another connection of the contact housing 55 to the electrical connection device 15 is also conceivable.

[0044] The contact housing 55 has a housing end face 56 at one side facing the observer. The contact housing 55 has at the housing end face 56 at least a first contact receptacle 70 and a second contact receptacle 75 arranged next to the first contact receptacle 70 in the x-direction. The first contact receptacle 70 and the second contact receptacle 75 may be formed identically. The first contact receptacle 70 and the second contact receptacle 75 are here arranged in the x-direction within a third row 80 which extends along a third straight line 81 parallel to the x-axis. The first and second contact receptacles 70, 75 are arranged in a first common xy-plane within which the third straight line 81 extends.

[0045] Additionally, the contact housing 55 may have a third contact receptacle 85 and a fourth contact receptacle 90 arranged adjacent to the third contact receptacle 85 in the x-direction, wherein the third contact receptacle 85 and the fourth contact receptacle 90 are arranged within a fourth row 95 which extends parallel to the x-axis along a fourth straight line 96. The third and fourth contact receptacles 85, 90 are arranged in a second xy plane within which the fourth straight line 96 extends. The third and fourth contact receptacles 85, 90 are arranged below the first and second contact receptacles 70, 75.

[0046] The first contact receptacle 70 and the third contact receptacle 85 are here arranged in the first common yz plane 52. Similarly, the second contact receptacle 75 and the fourth contact receptacle 90 can be arranged in the second common yz plane 53 within which the second and fourth plug-in contact receptacles 30, 45 are also arranged.

[0047] The contact receptacles 70, 75, 85, 90 are arranged within a matrix, wherein the matrix defines a predefined distance between the individual contact receptacles 70, 75, 85, 90. Advantageously, the predefined distance is constant. In the present embodiment, the contact housing 55 has a plurality of contact receptacles 70, 75, 85, 90 arranged side by side within the third and fourth rows 80, 95. Another configuration of the contact housing 55 is of course also conceivable. In particular, the number of contact receptacles 70, 75, 85, 90 can be adapted to the intended use.

[0048] The contact receptacles 70, 75, 85, 90 extend parallel to the y-axis through the contact housing 55 transversely to the housing end face 56 to a side, opposite the observer in [Fig. 1], of the contact housing 55. The contact receptacles 70, 75, 85, 90 are here produced in the form of a through opening within the contact housing 55. By way of example, the contact receptacles 70, 75, 85, 90 have an identical cross-section, for example rectangular. Another geometric configuration of the contact receptacles 70, 75, 85, 90 is of course conceivable. Another orientation of the contact receptacles 70, 75, 85, 90, in particular another orientation of the third and / or fourth row 80, 95, is also conceivable.

[0049] The contact device 20 has at least one first contact element 100 according to a first embodiment. The contact device 20 may further have a second contact element 105, a third contact element 110 and a fourth contact element 115. The first contact element 100 and the second contact element 105 are formed, by way of example, in an identical manner.

[0050] The first contact element 100 has a first connection section 120. The second contact element 105 has a second connection section 175. By way of example, the first contact element 100 engages at least partially in the first contact receptacle 70 via a first sub-region 240 of the first connection section 120.

[0051] The second contact element 105, which is arranged in close proximity to the first contact element 100 in the x-direction, partially engages in the second contact receptacle 75 via the second connection section 175.

[0052] Similarly, the third contact element 110 engages in the third contact receptacle 85 and the fourth contact element 115 partially engages in the fourth contact receptacle 90. An additional locking device can be provided here to fix the respective contact element 100, 105, 110, 115 in the respective associated contact receptacle 70, 75, 85, 90. This prevents the contact elements 100, 105, 110, 115 from slipping out of the contact housing 55 or the respective associated contact receptacle 70, 75, 85, 90 when mounting the contact device 20 on the electrical connection device 15.

[0053] [Fig.2] shows a sectional side view of the first contact element 100.

[0054] The first contact element 100 is implemented by way of example in the form of a pin contact. The first contact element 100 has by way of example, besides the first connection section 120, a first contact section 125, a second contact section 130 and a first shoulder section 135.

[0055] The first contact section 125 is connected to a tip 140 of the first contact element 100. The first contact section 125 is here designed in the form of a pin and has at least one contact surface 141 on its circumference. The first contact section 125 may here have at least one spring section 142, outside of which the contact surface 141 for establishing electrical contact with the first plug-in contact receptacle 25 is arranged.

[0056] The first connection section 120 connects in the z direction to the first contact section 125. The first connection section 120 has the first sub-region 240 and a second sub-region 245 connected to the first sub-region 240. The second sub-region 245 is exemplarily formed to be aligned with the first contact section 125 and to extend in the z direction. The second sub-region 245 connects directly to the first contact section 125.

[0057] The first connection section 120 has, by way of example, a rectangular basic shape, in particular an L-shaped basic shape. The first connection section 120 extends in a first material plane 145, in which the first material plane 145 and the first yz plane 52 overlap.

[0058] By first material plane 145 is meant the plane within which the material of the first connection section 120 extends after a rolling process, for example during a cold or hot rolling process. The first material plane 145 is formed planarly in the present embodiment. In the present embodiment, the first connection section 120 extends exclusively in the first material plane 145, so that the first connection section 120 extends completely in the first material plane 145 between the first contact section 125 and the second contact section 130. Likewise, the first contact section 125 and the second contact section 130 are arranged together for example in the first material plane 145 and thus in the first yz plane 52.

[0059] The first sub-region 240 is arranged between the second sub-region 245 and the second contact section 130 and extends substantially in the y-direction. The first sub-region 240 is exemplarily aligned with respect to the second contact section 130 and electrically and mechanically connects the second contact section 130 to the second sub-region 245.

[0060] The first connection section 120 has a first side surface 150 on a side opposite the observer, wherein the first side surface 150 is formed in a planar manner.

[0061] The first connection section 120 has a first outer contour 155 in a viewing direction parallel to the x-axis. The first outer contour 155 has a first cutting surface 160, wherein the first cutting surface 160 partially forms the first outer contour 155. By way of example, the first cutting surface 160 is inclined, preferably inclined perpendicularly or obliquely to the first material plane 145. The first cutting surface 160 connects to the first side surface 150 and is arranged inclined, preferably perpendicularly to the first side surface 150. The first cutting surface 160 extends parallel to the end face of the contact housing 55.

[0062] The first shoulder section 135 is arranged in the z-direction between the first cutting surface 160 and the first contact section 125. In [Fig. 2], the first shoulder section 135 is, by way of example, bent so as to protrude from the first material plane 145 in a direction away from the observer. The first shoulder section 135 is thus inclined relative to the first connection section 120. The first shoulder section 135 is by way of example formed in a curved manner and has a first curvature with a first curvature axis 136. The first curvature may be formed so as to extend in an arc shape, in particular along a first circular path.

[0063] [Fig. 3] shows a perspective representation of the contact device 20 shown in Figures 1 and 2.

[0064] For reasons of clarity, the representation of the contact housing 55 and the electrical connection device 15 is omitted in [Fig. 3].

[0065] By way of example, the second contact element 105 is arranged spaced apart in the x-direction next to the first contact element 100, on the right in [Fig. 3]. The second contact element 105 has, by way of example, an identical configuration to that of the first contact element 100, so that the contact device 20 can be mass-produced particularly simply and economically.

[0066] For a better understanding, and despite the fact that the configuration of the first and second contact elements 100, 105 is identical in the present embodiment, we will focus a little on the second contact element 105. Unless otherwise indicated, what has been explained for the first contact element 100 also applies to the second contact element 105.

[0067] The second contact element 105 has at least a second connection section 175 and a second shoulder section 170. The second connection section 175 extends in a second material plane 165, in which the second material plane 165 and the second yz plane 53 overlap. As a result, the first material plane 145 of the first connection section 120 is arranged parallel to and spaced apart from the second material plane 165 in the x direction.

[0068] The second connection section 175 has (in side view in an observation direction parallel to the x-axis) a second outer contour 180, in which the second outer contour 180 is identical to the first outer contour 155 due to the configuration identical to that of the first contact element 100. A configuration of the second outer contour 180 different from that of the first outer contour 155 is also conceivable.

[0069] The second outer contour 180 has a second cutting surface 181 on a side facing the contact housing 55. The second cutting surface 181 is, for example, arranged offset from the first cutting surface 160 in the y direction and is, for example, oriented parallel to the first cutting surface 160 and thus also parallel to the end face 56 of the contact housing 55. An oblique orientation of the second cutting surface 180 relative to the housing end face 56 and / or the first cutting surface 160 is also possible. The second shoulder section 170 is arranged so as to adjoin the second cutting surface 181. The first and second cutting surfaces 160, 181 are arranged parallel to each other.

[0070] [Fig.4] shows a section A, marked in [Fig.3], of the contact device 20 shown in [Fig.3].

[0071] The second shoulder section 170 is bent so as to exit the second material plane 165 and is arranged inclined relative to the second connection section 175. The second shoulder section 170 extends towards the first contact element 100. Likewise, the first shoulder section 135 of the first contact element 100 extends towards the second contact element 105. The second shoulder section 170 is formed in a curved manner and has a second curvature, in which the second curvature may be identical to the first curvature. The first curvature and / or the second curvature may here be arranged so as to extend in an arc shape, in particular along a second circular path. The second curvature has a second axis of curvature 182. The first axis of curvature 136 is arranged offset from the second axis of curvature 182 in both the x-direction and the y-direction.

[0072] The first shoulder section 135 and the second shoulder section 170 are arranged parallel to the first material plane 145 and thus in an offset manner. relative to each other in the y direction and additionally in the x direction.

[0073] The first shoulder section 135 has a first end surface 185 at a free end, wherein the first end surface 185 extends, for example, parallel to the first material plane 145. The second shoulder section 170 has a second end surface 190 at its free end, wherein the second end surface 190 may be oriented parallel to the first end surface 185. The first and second end surfaces 185, 190 are arranged between the first and second connection sections 120, 175 and spaced apart from each other in the x-direction.

[0074] In addition, the first contact element 100 may have a third shoulder section 195 and the second contact element 105 may have a fourth shoulder section 200. In the present embodiment, the third shoulder section 195 is formed by way of example in an identical manner to the second shoulder section 170, but the third shoulder section 195 is however bent so as to protrude from the first material plane 145 and extends on a side opposite the second contact element 105. The third shoulder section 195 connects to a third cutting surface 205 of the first outer contour 155 (in the second sub-region 245), which is arranged on the side, facing the housing end face 56, of the second sub-region 245. The third cutting surface 205 is formed by way of example in such a way that extend parallel to the first cutting surface 160.The third cutting surface may also be arranged obliquely inclined relative to the first cutting surface 160.

[0075] In the z-direction, the first shoulder section 135 and the third shoulder section 195 may, for example, be arranged at the same height. A width, in the z-direction, of the third shoulder section 195 and the first shoulder section 135 is also chosen to be identical, for example. As a result, the third shoulder section 195 is arranged between the third cutting surface 205 and the first contact section 125. The first shoulder section 135 and the third shoulder section 195 may also have a different geometric configuration.

[0076] The fourth shoulder section 200 of the second contact member 105 extends in a direction opposite to the first contact member 100 and is formed to extend parallel to the first shoulder section 135. In the z-direction, the first shoulder section 135 and the fourth shoulder section 200 are also formed to have, for example, the same width and are arranged at the same height (in the z-direction).

[0077] On the upper face, each of the shoulder sections 135, 170, 195, 200 has a force application surface 225 on a side opposite the electrical connection device 15, wherein the force application surface 225 is arranged in an inclined manner, preferably perpendicular to the cutting surface 160, 181, 205.

[0078] On the underside, each shoulder section 135, 170, 195, 200 has a bearing surface 230, in which the bearing surface 230 is oriented inclinedly, preferably perpendicular to the cutting surface 160, 181, 205 and / or to the first contact section 125. The force application surface 225 and the bearing surface 230 extend here, for example, parallel to each other. In the mounted state, the bearing surface 230 can rest on the upper side 65 of the electrical connection device 15.

[0079] [Fig.5] shows a sectional top view of the contact device 20 shown in [Fig.l].

[0080] The first connection section 120 has the first side surface 150 on a side facing the second contact element 105. The first side surface 150 is formed as a yz plane and lies in the first material plane 145. The first side surface 150 is advantageously formed planarly. The first shoulder section 135 runs laterally in front of the first side surface 150. The first shoulder section 135 here projects relative to the first side surface 150 in the y direction.

[0081] The first lateral surface 150 may here be, for example, an upper face of a sheet material of a blank from which the first contact element 100 is formed during the production of the first contact element 100.

[0082] The second connection section 175 has a second side surface 215 on a side facing the first contact element 100, wherein the first side surface 150 and the second side surface 215 are oriented parallel to each other. The second shoulder section 170 projects relative to the second lateral surface 215 in the direction of the first contact element 100. The second lateral surface 215 may, for example, be an underside of the sheet material from which the second contact element 105 is formed. The second cutting surface 181 adjoins the second lateral surface 215. The cutting surface(s) 160, 181, 205 is / are here the surface(s) along which a tool separates the corresponding connection section 120, 175 from the blank during the production of the contact element 100, 105, 110, 115.

[0083] The first shoulder section 135, the second shoulder section 170, the first lateral surface 150 and the second lateral surface 215 define an insulating air gap 220 between the first contact element 100 and the second contact element. 105. The first contact element 100 is electrically insulated from the second contact element 105 by means of the insulating air gap 220.

[0084] The two end surfaces 185, 190 have a spacing si. Similarly, the first end surface 185 and thus the first free end of the first shoulder section 135 are arranged spaced apart from the second free end and thus from the second end surface 190 of the second shoulder section 170 in the y direction.

[0085] A first minimum distance al between the second terminal surface 190 and the first lateral face 150 arranged facing the second terminal surface 190 as well as a second minimum distance a2 between the first terminal surface 185 and the second lateral surface 215 (the two distances al, a2 being oriented in the x direction) determines the insulating power of the insulating air gap 220. A third minimum distance between the first lateral surface 150 and the second lateral surface 215 defines a matrix module a3 of the matrix of the contact device 20.

[0086] Due to the arrangement, offset in the y direction, of the first shoulder section 135 relative to the second shoulder section 170, the matrix module a3 can be chosen to be particularly small and the first and second minimum distances a1, a2 can simultaneously be particularly large, so that a particularly good electrical insulating capacity is ensured by means of the insulating air gap 220. The contact device 20 is thus particularly compact.

[0087] Accordingly, the number of first and second contact elements 100, 105 may be greater in the case of an extension obtained orthogonally identically in the x direction of the contact housing 55.

[0088] In the present embodiment, the insulating air gap 220 can thus be formed as an air gap so that the contact device 20 can be kept particularly short in the y direction. As a result, the weight of the system 10 is also reduced. In particular, it is possible to dispense with the arrangement of an insulating means or a further contact housing in the region of the insulating air gap 220.

[0089] Furthermore, the third and fourth contact elements 110, 115 may also be arranged directly under the first and second contact elements 100, 105, wherein good electrical insulation is simultaneously ensured between the contact elements 100, 105, 110, 115. [Fig. 6] shows a side view of the third contact element 110 of the system 10 shown in [Fig. 1].

[0090] The third contact element 110 is formed substantially identically to the first contact element 100 shown in [Fig. 2], wherein, unlike the first contact element 100 shown in [Fig. 2], a first sub-region 240 extending in the y-direction is formed shorter than the first sub-region 240, shown in [Fig. 2], of the first contact element 100.

[0091] Furthermore, a second sub-region 245, extending in the z-direction, of the first connection section 120 of the third contact element 110 is exemplarily formed shorter in the z-direction than is the second sub-region 245 of the first connection section 120. Accordingly, the first contact section 125 of the third contact element 110 can engage in the third plug-in contact receptacle 40 arranged within the second row 50 and said third contact element can be arranged below the first contact element 100 in the first common yz-plane 52. Likewise, the first sub-region 240 of the third contact element 110 may at least partially engage the third contact receptacle 85 of the contact housing 55. In the present embodiment, the third contact element 110 and the fourth contact element 115 are formed identically to each other.

[0092] Thanks to a configuration of the third and fourth contact elements 110, 115 similar to that of the first and second contact elements 100, 105, the third and fourth contact elements 110, 115 also have, within the arrangement of the second row 50, a particularly wide insulating air gap 220 for the purpose of electrical insulation.

[0093] [Fig.7] shows a production flowchart of the contact element 100, 105, 110, 115 shown in Figures 1 to 6. [Fig.8] shows the contact element 100, 105, 110, 115 before and during a third process step 310. [Fig.9] shows the section shown in [Fig.4] during a seventh process step 330.

[0094] In a first process step 300, a plate-shaped and / or strip-shaped blank, preferably thin-walled, for example a sheet material, is fed to a production machine.

[0095] In a second method step 305 following the first method step 300, the outer contour 155, 180 is cut and finished using a cutting means, for example a stamping tool or a laser. The cutting surfaces 160, 181, 205 are formed here using the cutting means. In addition, the sub-regions 240, 245, 250 are formed by the cutting. The sub-regions 240, 245, 250 are not folded relative to each other. The shoulder sections 135, 170, 195, 200 are produced here (see [Fig. 8]) in the form of laterally arranged plates which are, for example, tongue-shaped.

[0096] In a third method step 310 which follows the second method step 305 or which can be carried out essentially simultaneously with the second method step 305, the shoulder section 135, 170, 195, 200 is bent out of the material plane 145, 165 by means of a punch and a die. The two shoulder sections 135, 170, 195, 200 arranged opposite each other can be bent out of the material plane 145, 165 for example in a counter-rotating in positive and negative x directions (as symbolically represented in [Fig.8] by means of two curved arrows).

[0097] The spring portions 142 of the first contact section 125 may be formed in a fourth process step 315 that follows the third process step 310.

[0098] In a fifth method step 320, the second contact section 130 of the contact element 100, 105, 110, 115 is inserted into the respectively associated contact receptacle 70, 75, 85, 90 of the contact housing 55. This operation is repeated until all necessary contact receptacles 70, 75, 85, 90 are occupied by the respective corresponding contact element 100, 105, 110, 115 and until the contact device 20 is fully equipped. For this purpose, the individual contact elements 100, 105, 110, 115 can also be connected to each other via a subsection, in particular a transport belt, in order to transport the contact elements 100, 105, 110, 115 in an automated manner. Before insertion into the contact receptacle 70, 75, 85, 90, the corresponding contact element 100, 105, 110, 115 is separated from the subsection, for example from the transport belt.

[0099] After insertion, the contact housing 55, in operative connection with the contact element 100, 105, 110, 115 respectively arranged in the contact receptacle 70, 75, 85, 90, immobilizes the contact elements 100, 105, 110, 115 during transport of the fully equipped contact device 20.

[0100] In a sixth method step 325 following the fifth method step 320, the contact device 20 is mounted on the electrical connection device 15 in such a way that the first contact sections 125 (of all contact elements 100, 105, 110, 115) are aligned above the respective associated plug-in contact receptacle 25, 30, 40, 45.

[0101] In a seventh method step 330 following the sixth method step 325, the tool 235 (shown in dotted lines in [Fig. 4]) is introduced into the insulating air gap 220 in such a way that a tool end surface of the tool 235 rests on the force application surface 225. The tool 235 can also rest simultaneously on all the force application surfaces 225 (preferably all the contact elements 100, 105, 110, 115).

[0102] A pressing force FP (see [Fig. 8]) is applied to the shoulder section 135, 170, 195, 200 by means of the tool 235, said force enabling the first contact section 125 to be pressed into the respective associated plug-in contact receptacle 25, 30, 40, 45. The pressing by means of the tool 235 can take place simultaneously for all the contact elements 100, 105, 110, 115, so that that the contact device 20 can be brought into electrical contact with the electrical connection device 15, and mounted, particularly quickly and easily.

[0103] Due to the offset arrangement of the shoulder sections 135, 170, 195, 200, the first contact sections 125, arranged within the first and second rows 35, 50, of the first to fourth contact elements can be pressed in a single operation by means of the (pressing) tool 235 (dotted in [Fig. 8]) into the respective associated plug-in contact receptacle 25, 30, 40, 45 with a single rectilinear lowering movement parallel to the z-axis.

[0104] By arranging the contact elements 100, 105, 110, 115 in two rows, all force application surfaces 225 are uncovered in the top view and are therefore accessible in the z direction by a simple linear rectilinear movement of the tool 235 from top to bottom. Consequently, simple kinematics are sufficient to actuate the tool 235.

[0105] It is further possible to dispense with additional pressure sleeves, insulating means or other contact housings, for example made of plastic, for applying the pressure force by the tool 235 to the contact element 100, 105, 110, 115. In the present embodiment, the force is applied directly and immediately.

[0106] A driving depth of the first contact section 125 into the respective associated plug-in contact receptacle 25, 30, 40, 45 is limited by the stop of the contact surface 230 against the upper face 65 of the electrical connection device 15. This ensures that the contact element 100, 105, 110, 115 is not driven too far and that reliable electrical contact is ensured between the contact element 100, 105, 110, 115 and the associated plug-in contact receptacle 25, 30, 40, 45.

[0107] After the first contact section 125 has been pressed into the respective associated plug-in contact receptacle 25, 30, 40, 45, the tool 235 can be removed from the insulating gap 220.

[0108] By cutting out the connection section 120, 175, the outer contour 155, 180 is created in a defined manner within the production process without it being necessary to additionally bend the sub-regions 240, 245, 250 relative to each other to form the outer contour 155, 180, as shown in FIGS. 1 to 7.

[0109] The present embodiment has the advantage that tolerances, in particular an orientation tolerance or an angular tolerance of the first contact section 125 relative to the second contact section 130, can be particularly well respected, or that the orientation of the first contact section 125 relative to the second contact section 130 is particularly dimensionally accurate, since accumulations of tolerances encountered during individual successive bending steps, in particular as they previously existed when folding the individual sub-regions 240, 245, 250, are avoided. The contact element 100, 105, 110, 115 is furthermore particularly simple and inexpensive to manufacture in one piece and from the same material.

[0110] This has the advantage that the first contact section 125 is oriented in a particularly dimensionally stable manner, preferably perpendicular, to the electrical connection device 15, so that warping or incorrect insertion of the first contact section 125 into the associated plug-in contact receptacle 25, 30, 40, 45 is reliably prevented. This achieves high manufacturing accuracy.

[0111] It should be noted that the method steps 300 to 330 described in [Fig. 8] are preferably implemented in the order indicated. Of course, another order can also be chosen (insofar as this is relevant).

[0112] [Fig. 10] shows a top view of a development of the contact device 20 shown in Figs. 1 to 9.

[0113] The development shown in [Fig. 10] is substantially identical to the contact device 20 shown in Figures 1 to 9. Only the differences between the development shown in [Fig. 10] and the embodiment shown in Figures 1 to 9 are commented on below.

[0114] In [Fig. 10], the matrix module a3 is reduced compared to the embodiment of the contact device 20 shown in Figures 1 to 9. This also means that the first minimum distance a1 and the second minimum distance a2 are reduced compared to Figures 1 to 9.

[0115] The matrix module a3 is chosen by way of example in such a way that the first shoulder section 135 and the second shoulder section 170 are arranged in the y-direction so as to overlap. An overlap in the y-direction means here that if two components, for example the first shoulder section 135 and the second shoulder section 170, are projected in the y-direction into a projection plane formed as the xz-plane, these overlap in the projection plane.

[0116] By virtue of the shoulder sections 135, 170, 195, 200 angled out of the material plane 145, 165 and arranged offset in the y direction, the matrix module a3 can be chosen to be particularly small. This avoids direct mechanical and electrical contact at the end surfaces 185, 190 of the shoulder sections 135, 170, 195, 200, for example the first and second shoulder sections 135, 170. This prevents a short circuit between the shoulder sections 135, 170, 195, 200.

[0117] [Fig. 11] shows a top view of a contact device 20 according to a second embodiment.

[0118] The contact device 20 shown in [Fig. 11] is essentially identical to the contact devices 20 shown in Figures 1 to 9. With the difference, however, that the number of contact elements 100, 105, 110, 115 is reduced compared to the contact device 20 shown in Figures 1 to 9.

[0119] Due to the arrangement of the shoulder sections 135, 170, 195, 200 of the contact elements 100, 105, 110, 115 described above, the shoulder sections 135, 170, 195, 200 are arranged offset in the y direction. In particular, the second shoulder section 170 is here arranged in the y direction between two first shoulder sections 135 of the first and third contact elements 100, 110 so as to adjoin the insulating air gap 220 or two contact elements 100, 105, 110, 115 arranged in close proximity in the x direction. As a result, even with a particularly small matrix module a3, the second minimum distance a2 can be kept particularly large and a particularly good insulating capacity of the insulating air gap 220 can be guaranteed.

[0120] [Fig. 12] shows a perspective view of a contact device 20 according to a third embodiment.

[0121] The contact device 20 is essentially identical to the contact device 20 shown in Figures 1 to 9. With the difference, however, that the embodiment shown in [Fig. 12] dispenses with the second and fourth contact elements 105, 115.

[0122] The respective first connection section 120 of the first and third contact elements 100, 110 may additionally have a third sub-region 250 in addition to the first and second sub-regions 240, 245, wherein the third sub-region 250 is arranged, for example, to adjoin the first sub-region 240 on the side facing the contact housing 55. The sub-regions 240, 245, 250 may here be oriented so as to be inclined perpendicularly and / or obliquely to one another. In [Fig. 12], it is particularly clear that the sub-regions 240, 245, 250 are all arranged exclusively in the first material plane 145.

Claims

1. Claims Contact device (20) for establishing contact with another contact device (21) of a system (10), - having a first contact element (100) and a second contact element (105), - wherein the first contact element (100) has a first shoulder section (135), a first contact section (125), a second contact section (130) and a first connection section (120), - wherein the first contact section (125) is formed so as to enable contact to be made with a first plug-in contact receptacle (25) of the other contact device (21), - wherein the first connection section (120) electrically and mechanically connects the first contact section (125) to the second contact section (130), - wherein the first contact section (125) and the first connection section (120) are formed at least partially in a first material plane (145), - wherein the first shoulder section (135) is formed at the first connection section (120) and extends transversely relative to the first connection section (120) away from said first connection section (120), - wherein the first shoulder section (135) is bent so as to exit the first material plane (145), - wherein the second contact element (105) is arranged offset transversely to the first material plane (145), - wherein the second contact element (105) has a second shoulder section (170) and a second connection section (175) extending at least partially in a second material plane (165), - wherein the second shoulder section (170) is formed at the second connection section (175) and extends transversely to the second connection section (175) from the second connection section (175) towards the first contact element (100), - wherein the second shoulder section (170) is bent so as to protrude from the second material plane (165), - wherein the first shoulder section (135) of the first contact element (100) and the second shoulder section (170) of the second contact element (105) are arranged offset from each other in a direction parallel to the first material plane (145), and the first shoulder section (135) of the first contact element (100) and the second shoulder section (170) of the second contact element (105) are arranged in a direction (y), parallel to the first material plane (145), so as to overlap so that when the first shoulder section (135) and the second shoulder section (170) are projected in this direction (y) into a projection plane (xz) perpendicular to the first material plane (145),the first shoulder section (135) of the first contact element (100) and the second shoulder section (170) of the second contact element (105) overlap in said projection plane (xz).,

2. Contact device (20) according to claim 1, - wherein the first material plane (145) and the second material plane (165) are arranged side by side in a parallel and spaced manner.

3. Contact device (20) according to any one of the preceding claims, - wherein the first shoulder section (135) is bent so as to exit the first material plane (145) with a first curvature, preferably in the form of an arc, particularly preferably following a circular path.

4. Contact device (20) according to any one of the preceding claims, - wherein the second shoulder section (170) is formed in a curved manner with a second curvature, preferably in an arc shape, particularly preferably following a further circular path, - wherein the first curvature is counter-rotating with respect to the second curvature.

5. Contact device (20) according to any one of the preceding claims, - wherein the first connection section (120) has a first cutting surface (160) and, on a side facing the second connection section (175), a first side surface (150), - wherein the first cutting surface (160) adjoins the first side surface (150) and the first side surface (150) is arranged inclined relative to the first cutting surface (160), - wherein the first shoulder section (135) is formed at the first connection section (120) between the first contact section (125) and the first cutting surface (160), - wherein the first shoulder section (135) passes in front of the first side surface (150) and projects relative to the first side surface (150).

6. Contact device (20) according to claim 5, - wherein the second connection section (175) has a second cutting surface (181) and a second side surface (215) facing the first connection section (120), - wherein the second cutting surface (181) adjoins the second side surface (215), - wherein the second side surface (215) is arranged parallel to the first side surface (150) and opposite the first side surface (150), - wherein the second shoulder section (170) projects from the second side surface (215) towards the first side surface (150).

7. Contact device (20) according to claim 6, - having a contact housing (55) with a first contact receptacle (70) and a housing end face (56), - wherein at least the second contact section (130) of the first contact element (100) engages in the first contact receptacle (70), - wherein the first cutting surface (160) is oriented parallel or inclined relative to the housing end face (56).

8. Contact device (20) according to any one of the preceding claims, - wherein the first connection section (120) has a first sub-region (240) and a second sub-region (245) adjoining the first sub-region (240), - wherein preferably the second sub-region (245) is oriented aligned with respect to the first contact section (125), - wherein the first sub-region (240) and the second sub-region (245) are oriented inclined with respect to each other, - wherein the first sub-region (240) is arranged so as to adjoin the second contact section (130), - wherein preferably the second contact section (130) is arranged aligned with respect to the first sub-region (240), - wherein the first sub-region (240), the second sub-region (245) and the second contact section (130) are formed so as to extend in the first plane of material (145).

9. Contact device (20) according to any one of the preceding claims, - wherein the first contact element (100) has a third shoulder section (195), - wherein the third shoulder section (195) is formed at the first connection section (120) on a side opposite the first shoulder section (135), - wherein the third shoulder section (195) extends transversely to the first connection section (120) from the first connection section (120) in a direction opposite that of the first shoulder section (135), - wherein the third shoulder section (195) is bent so as to exit the first material plane (145) in a direction opposite that of the first shoulder section (135).

10. Contact device (20) according to any one of the preceding claims, - wherein the second contact element (105) has a fourth shoulder section (200), - wherein the fourth shoulder section (200) is formed at the second connection section (175) on a side opposite the second shoulder section (170), - wherein the fourth shoulder section (200) extends transversely to the second connecting section (175) from the second connecting section (175) in a direction opposite to that of the second shoulder section (170) and is bent so as to exit the second material plane (165) in a direction opposite to that of the second shoulder section (170).

11. System (10), - having a further contact device (21) and a contact device (20) according to any one of the preceding claims, - wherein the further contact device (21) has at least one first plug-in contact receptacle (25), - wherein the first contact section (125) of the first contact element (100) engages in the first plug-in contact receptacle (25) and the first contact section (125) forms an electrical contact with the first plug-in contact receptacle (25).

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