Connector

Abstract

TITLE: Connector Connector comprising a contact housing (2) for an opposing contact (30), a contact blade (3), * the contact housing (2) having a first wall (21) and a second wall (22) opposite each other, * the blade (3) is between the first wall (21) and the second wall (22). The housing (2) is mainly made of a first material (M1). The blade (3) is made of a first material (M1) in a first segment (4) and mainly of a second material (M2) in an adjacent second segment (4). The shear modulus of the second material (M2) is at least 1.5 times the shear modulus of the first material (M1). Figure 2a

Description

Title of the invention: Connector FIELD OF THE INVENTION

[0001] The present invention relates to a connector. STATE OF THE ART

[0002] According to the state of the art, various electrical connectors are known for receiving an opposing contact element. Such connectors can be made in one piece, i.e. from a metal strip (generally made of a copper alloy) or from a sheet metal by stamping and bending. One-piece contacts in copper alloys have relatively low primary retaining forces in the contact chamber. In addition, they have a high risk of plastic deformation during insertion and a tendency to relax (of varying degrees depending on the alloy), the normal contact forces decreasing with time and temperature; for example the contact forces exerted by a contact strip on an opposing, inserted contact element; the risk is thus that of premature breaking of the contact. Such a one-piece connector is known from DE 10 2007 040 937 B3.

[0003] Two-part contacts are also known. In this case, a resilient outer part (also called a spring or outer contact housing) is made of steel as a single element and is folded over a separately manufactured inner contact part from another sheet metal (also called a "contact half"); this is made of a material with good electrical conductivity, such as, for example, copper. In this way, the primary retaining force in the contact chamber can be increased because this is then exerted by the separate outer contact part made of steel. In addition, the spring made of steel can support the force of the contact blade. Such a conductor made of two assembled parts, which consists of an inner contact part and an elastic outer part initially manufactured separately, is known from DE 102 48 809 AL

[0004] Improving the mechanical properties of one-piece connectors that must also have high electrical conductivity requires the use of thicker sheets or special copper alloys. These alloys must increase the modulus of elasticity or the shear modulus of copper, which is inherently soft and ductile, so that even with a low sheet thickness, the necessary primary holding forces are obtained and the normal contact force exerted by the contact strips on the opposite, plugged-in contact element is maintained during the connector life. However, the use of thicker sheets is often impossible due to the dimensions imposed on the connectors. The use of highly engineered copper alloys is more expensive than using normal copper or simple copper alloys.

[0005] Two-part contacts are complicated and expensive to produce because to produce the elastic outer part or the over-spring, a special stamping-bending tool is required, i.e. another element in the stamping-bending tool; the two parts, initially manufactured separately (inner contact part and elastic outer part) must be assembled after their manufacture. In addition, the doubling of the material in certain places can greatly limit the possibilities of miniaturizing such two-part contacts.

[0006] PURPOSE OF THE INVENTION

[0007] There is thus a need for connectors which meet the high mechanical requirements concerning the primary holding forces in the contact chamber receiving the connector in a satisfactory manner, and which, alternatively or in addition, meet, in a durable manner, the high mechanical requirements concerning the normal contact force with respect to an opposing contact element, engaged in the connector and which has only a low relaxation and, in addition, can be manufactured in a simple and economical manner. It is further desirable that the connector has a high electrical conductivity in the segments through which the current flows.

[0008] DISCLOSURE AND ADVANTAGES OF THE INVENTION

[0009] For this purpose, the invention relates to a connector comprising: a contact housing oriented in an axial direction to receive an opposing contact element, a contact strip, the contact housing having a first wall and a second wall opposite relative to the radial direction; transversely to the radial direction; the contact strip is provided in the contact housing between the first wall and the second wall and relative to the radial direction; the contact housing is made mainly of a first material; a first segment of the contact strip is made of a first material and a second segment adjacent to the first segment; mainly in a second material in the second segment between the first segment and the first wall overlaps the first segment and the first wall;the shear modulus of the second material is at least 1.5 times the shear modulus of the first material or the modulus of elasticity of the second material exceeds the modulus of elasticity of the first material by at least 1.5 times; the contact housing and the contact strip are produced in the form of a stamped part folded from a single sheet. ;

[0010] In other words, the connector has a contact housing oriented in the axial direction to receive an opposing contact element as well as a contact blade. The contact housing has a first wall and a second wall that oppose each other with respect to a radial direction transverse to the axial direction, the contact strip in the contact housing being located between the first wall and the second wall with respect to the radial direction. The contact housing is made primarily of a first material. The contact strip has a first segment, primarily made of the first material and a second segment adjacent to the first segment is primarily made of a second material. The second segment is located between the first segment and the first wall. This second segment overlaps the first segment and the first wall. The shear modulus of the second material is at least 1.5 times the shear modulus of the first material. Alternatively or additionally, the modulus of elasticity of the second material is at least 1.5 times the modulus of elasticity of the first material.It is thus planned that the contact housing and the contact strip are produced from a single sheet in the form of a pressed-bent part.

[0011] This results in the advantage of a one-piece connector, simple to manufacture and which, at the same time, has a high, durable normal contact force for the contact strip because the latter bears by its first segment against the second segment made of a mechanically more rigid material; this makes any separate overspring unnecessary and thus makes it possible to have a lower thickness of the first material for the first segment compared to a connector in which the permanent normal contact force is provided by the second segment made of a second material. The fact that the second segment has the second material which ensures the mechanical strength of the first segment of the contact strip thus makes it possible to combine the advantages of the one-part connector with those of the two-part connector. For the first material, it is possible, for example, to use a very economical material because this material is not necessarily a special alloy.At the same time, a simpler and therefore more economical stamping-bending tool can be used because a separate over-spring is not produced which is then folded down onto the contact housing. As the over-spring in conventional designs is produced with a second stamping-bending tool, this second stamping-bending tool (to produce the over-spring) and the tool which folds it down onto the contact housing is avoided.

[0012] For example, it is advantageous for the first segment or the first material to have a very high electrical conductivity. This may, for example, be the electrical conductivity of the first material being at least three times and preferably four times the electrical conductivity of the second material.

[0013] The expression that the first segment is made mainly of the first material means that the first segment of the contact strip is made of more than 50% of the first material, for example, at least 70%, preferably more than 85% and particularly preferably more than 95%. The deviations per compared to a production made entirely with the first material may be related, for example, to the production by the stamping-bending process or to a possible covering of the surface of the first material which is, for example, applied to reduce friction or protect it against corrosion. Such a surface coating may exist before the stamping-bending operation, but it may also be applied after this on the manufactured connector. In the same way, the above considerations apply to the expression according to which the second segment is mainly made from the second material, that is to say more than 50%, for example, at least 70%, preferably at least 85% and particularly preferably more than 95%.

[0014] The second segment is located between the first segment and the first wall in the radial direction.

[0015] Since the connector has a contact strip, the advantage is that the opposing contact element is mechanically contacted in the engaged state. The contact strip is preferably elastically reversibly deformable. It can, for example, be elastically prestressed in the radial direction, for example, relative to an opposing contact element that is plugged in, so that in the engaged state of the opposing contact element, there is a defined normal force or normal contact force, for example between 1N and 10N, for example 1N, 2N, 3N, 4N, 5N, 6N, 7N, 8N, 9N, 10N, or in other embodiments, a higher normal contact force in the radial direction. This makes it possible to design the connector in a manner that is particularly stable with respect to contact breaks under vibration stress.

[0016] The connector may have, precisely, one contact strip. But, it may also have several contact strips, for example, two, three, four, five, six or more contact strips. In such a case with several contact strips (a set of contact strips), at least one of the contact strips is oriented on the first segment which is made mainly of the first material and a second segment which is made mainly of the second material and which is connected to the first segment (in particular directly); the second segment is between the first and the first wall and it overlaps the first segment and the first wall.

[0017] Advantageously, several contact strips of this set of contact strips of this device project relative to the first and second segments; it may thus happen that some of the first segments are located between the second segment and the second wall or the second segment and a third wall or the second segment and a fourth wall, etc. and overlap the respective second segment and the respective wall or sandwich them between the second segment and the respective wall.

[0018] Particularly advantageously, each of the contact strips of the set of contact strips of such a construction projects from the first segment and the second segment. It can be provided that for contact strips that face each other in the radial direction, a contact strip of the first embodiment is formed from the first and second segments and that the opposite contact strip does not have a second segment in the arrangement described above or the combination of materials. In such an embodiment, excessive thickness in the radial direction is avoided while having a high, sustainable normal contact force, because one of the contact strips has the second segment that also exerts a force in the direction of the opposite contact strip.

[0019] The first material preferably has a high electrical conductivity, so that the electrical resistance of the current path from the opposing contact element through the front strip to the connector and from there continuing to a line provided on the connector is particularly low.

[0020] The two materials (first material and second material) can have the same thickness. However, different thicknesses are also provided.

[0021] For example, the first material has a first thickness and the second material a second thickness. For example, it may be provided that the first thickness and the second thickness are less than 0.5 mm. The first thickness or the second thickness may be in a range between 0.2 mm and 0.3 mm and, for example, be equal to 0.2 mm or 0.25 mm or 0.3 mm. In other developments, the second step is in a range between 0.05 mm and 0.3 mm, being, for example, equal to 0.05 mm or 0.1 mm or 0.15 mm or 0.2 mm. The first thickness may also correspond to the indicated thicknesses or the material thicknesses. It is preferentially provided that the second thickness is less than the first thickness. This means that, for example, the first thickness will be equal to at least 1.2 times the second thickness.This allows the development of a second, thinner material, reducing cost and weight while still ensuring a normal, stabilized, and permanent contact force exerted on the contact blade.

[0022] The contact housing has, for example, a rectangular or round or triangular or oval section.

[0023] The production of a connector can be done, for example, by providing a metal sheet or strip for a bending and folding tool; the metal sheet or strip has two areas with different materials, the first material and the second material inseparably connected (which cannot be separated without destruction), for example, by a melting or casting process, a welding process, a printing process, a bonding process or the like. In principle, it is also possible to join two sheets of different materials (a first material and a second material) directly before the stamping and bending operation from two non-separable metal sheets or strips, joined into a single metal sheet or strip, for example, by welding followed directly by the stamping-bending process to manufacture the connectors. In such a case, it is also possible to provide that the assembly step of the metal sheet or strip formed from two metal sheets or strips is carried out in the same tool in which the stamping-bending is carried out. However, two separate tools can also be provided, for example, an assembly tool and a stamping-bending tool.

[0024] As an example, it is provided that after having provided the single sheet of the housing of contact and the contact strip with its first segment and its second segment (and possibly other elements of the connector) in one step or in a series of steps, cutting and stamping is carried out from the sheet metal or metal strip; after the stamping operation, a stamping plate is obtained. Thus, in another step or at the same time as the stamping, it is also possible to carry out plastic deformation (printing) of certain elements, for example, of the first or second segment of the contact strip, for example, in a first segment or second segment of the contact strip, an elastically reversible spring prestress is applied, which acts, for example, in the radial direction in the finished connector. Furthermore, by way of example, in another step, the second segment of the contact strip (and possibly other elements of the connector such as, for example, a latching tab, etc.) is folded back.), along a fold line transverse to the axial direction, of approximately 180°; thus the second segment of the contact strip comes to rest in the vicinity of the first contact segment of the contact strip.

[0025] Furthermore, by way of example, in another step, the different segments of the stamping plate are deformed at the bending lines which are substantially or precisely parallel to the axial direction to obtain the contact housing; the second segment of the contact strip is supported between the first wall of the contact housing and the first segment of the contact strip by overlapping the first segment and the first wall at least partially, for example, over at least 25% of its length or over at least 50% of its length or over at least 70% of its length. Thus, in this succession of steps given solely by way of example, the second segment of the contact strip is surrounded by the first wall and the second segment of the contact strip or is sandwiched in the radial direction.The first segment which has mainly the first mechanically less hard material rests on the second segment made mainly with a second harder material and allows to exert, permanently, a high normal contact force on an opposite contact element engaged in the connector (by . example plugged in).

[0026] The sequence of steps described above is given solely as an example and different steps may be exchanged or omitted. In addition, other steps may be provided.

[0027] In the context of the present description, the expression “comprising” is synonymous with “having” unless otherwise indicated.

[0028] It should also be emphasized that the conjunction "or" used in the description and in the claims has the double meaning of the logical function "or" inclusive and "or" exclusive. This conjunction thus advantageously replaces the expression and / or.

[0029] Since the connector is designed as a contact socket (female contact), the advantage is that the connector is designed in a particularly simple manner as a pressed-bent part. Furthermore, it is advantageous to have a particularly secure and reliable contact of the opposing contact element. Furthermore, the connector is in contact with the opposing contact element in a defined shape.

[0030] According to a development, the connector has a connection area for fixing an electrical line, this connection area joining the contact housing or the contact strip (for example, its first segment or its second segment); the connection area is made mainly with the first material; the connection area with the contact housing and the contact strip is made from a single sheet as a pressed-bent part. This results in the advantage that the connector is particularly compact. Furthermore, the connector is particularly simple and economical to produce in this way.

[0031] The expression that the connection zone is mainly made of the first material means that it is made with more than 50% of this first material, preferably more than 70%, preferably more than 85% and particularly preferably more than 95%. The considerations developed above concerning the necessary contents of the second material or of the surface coatings apply analogously to the connection zone.

[0032] The connection area may comprise, for example, a pair of crimping tabs or two pairs of crimping tabs (insulation crimping and conductor crimping). It is further possible to envisage the connection area comprising connecting tabs for connecting wires of the line or for connecting the line or a welding surface for welding the line. It is also possible to envisage the connection area being produced as a connection by cutting and clamping.

[0033] According to a development, the second segment is in mechanical contact at a first point with the first wall, in particular in a detachable manner without destruction; the second segment is in contact at a second point with the first segment, by a mechanical contact, in particular detachable without destruction. It is provided that the second point is not located on the junction edge between the first segment and the second segment. Thus, advantageously, the first segment of the contact strip is supported in a particularly reliable and stable manner; the normal contact force can maintain an acceptable, lasting level. For example, the first point has a larger first contact surface between the first wall and the second segment than the second point which has a second contact surface between the first segment and the second segment. The first contact surface or the second contact surface preferably have, respectively, a first normal to the surface (first contact surface) or a second normal to the surface (second contact surface) which extends mainly in the radial direction (+ / -40° relative to the radial direction).Thus, a normal contact force of the first segment will be distributed to the opposite contact element by the second segment over a large area of ​​the contact housing, which reduces the pressure exerted on separate points of the contact housing and thus avoids relaxation or deformation of the contact housing.

[0034] At the same time, the second segment increases the point pressure exerted on the first segment to permanently apply a high normal contact force to the opposing contact element. Preferably, the second segment is in permanent mechanical contact with the first wall and the first segment (contact which separates without destruction). Preferably, the second segment is applied detachably or freely against the first wall or against the first segment. This can also be the case for the opposing contact element which is not engaged. The second segment thus preferably serves not only as a stop or elastic buffer, for example, against vibrations or for large movements of an opposing, inserted contact element, but also permanently participates in the application of the normal contact force to develop a prestress, in particular elastically reversible in the radial direction.At the same time, a material connection between the second segment and the first wall or between the second segment and the first segment is removed; the junction edge between the first material and the second material is not taken into account here; this simplifies manufacturing.

[0035] Since the contact strip has a printed contact point, this advantageously produces a defined contact point on the opposing contact element in the plugged-in state. Furthermore, advantageously, a particularly low throughput resistance is achieved by engaging the opposing contact element.

[0036] The fact that the second point is at most 2 mm, particularly preferably at most 1 mm and extremely preferably at most 0.5 mm away from the contact point, has the advantage that the mechanical assistance provided by the second segment or the support of the first segment produces a component of force in the radial direction, as large as possible and thus it best supports the normal contact force.

[0037] This means in particular that the second point considered in the axial or lateral direction is at most 2 mm, preferably at most 1 mm and particularly preferably at most 0.5 mm away from the contact point, i.e. at an axial distance of at most 2 mm, preferably at most 1 mm and particularly preferably at most 0.5 mm from the contact point. By way of example, this axial distance between the respective center of the second point and the contact point is defined in this way. This means that the second point is not a point on the junction edge between the first material and the second material.

[0038] According to a development, a part of the contact housing or a part of the first segment of the contact strip is made of the second material. For example, the front part of the contact housing or of the first segment of the contact strip facing the opposite contact element is made at least in part of the second material. In addition, it can, for example, be provided that by stamping, elements which form the contact housing have at one end a part composed of the second material of the metal strip or the sheet metal. It is also possible to envisage a method of transforming the parts of the stamping plate which are formed from the part of the sheet metal containing the second material.Thus, advantageously, solely by way of example, a front surface of the contact housing facing the opposite contact element or the first segment of the contact blade will be more robust, for example, to be more resistant to incorrect attempts to plug in the opposite contact element. In this way, a mechanical reinforcement can advantageously be achieved on a side surface parallel to the axial direction or side wall (for example, the first, second, third or fourth wall) of the contact housing.

[0039] According to a development, the contact housing is closed at the periphery, along the peripheral direction rotating around the axial direction. This results in the advantage that the connector, when engaged in the contact chamber of a connector housing, will not be damaged, even if significant forces are exerted during insertion. This is particularly important, for example, for miniaturized connectors, having sheet thicknesses of less than 0.5 mm, or even less than 0.4 mm and even less than or equal to 0.25 mm. It is further advantageous that, in this way, the contact blade is enclosed like a cage or a box. The contact blade will be well protected against external actions, against deformation, for example, the engagement of the connector in a contact chamber. There is also the advantage of the stability of the contact housing which is increased in this way, for example, against radially acting forces because the walls of the closed form support themselves by stabilizing themselves. Furthermore, it is advantageous in this way that forces acting radially from the outside on the contact blade (especially on its first segment) can always bear against the contact housing, which increases the stability of the connector and also promotes the lasting maintenance of the normal contact force.

[0040] According to a development, the connector has a hooking tab projecting outwards and which can be elastically deformed inwards reversibly. Thus, it is provided solely by way of example to produce the hooking tab mainly with the second material. Solely by way of example, the hooking tab can be produced on the contact housing or on a wall of the contact housing, in particular in one piece with the latter. The hooking tab advantageously makes it possible to have a particularly high primary holding force when the connector is engaged in the contact chamber of a connector housing. The hooking tab can deflect obliquely, radially outwards relative to the connector.

[0041] Embodiments may be provided which have precisely one hooking tab. However, embodiments may also be provided having more than one hooking tab, for example, 2, 3, 4 or more hooking tabs. In such a case, it is advantageous for each of the hooking tabs to be made at least mainly of the second material.

[0042] This or these hooking tabs may also be called "primary hooking tabs" or "primary locking elements". They may be made so that when the connector is engaged, they hook onto an undercut in the contact chamber of the connector housing so as to allow the connector to be extracted from the contact chamber (without damage) and without requiring an unlocking tool. For durable locking of the connector, a secondary locking element is provided which is, for example, slid into the connector housing to come behind the undercut of the connector so that it cannot be extracted from the contact chamber.

[0043] According to a development, the first material is chosen from the group comprising: copper, copper alloy, aluminum, aluminum alloy, which thus has the advantage of a particularly high electrical conductivity of the connector. There is the advantage of a low electrical resistance between the connector and the opposite contact element because this opposite contact element is in electrical contact with the contact strip. It is further advantageous that the electrical resistance of the path or current path to the line connected to the connector is low. It is further advantageous that the passage resistance from the connector to the electrical line connected to the connector is low. Finally, there is the advantage that the stamping process and the bending process are simple because the materials proposed as raw materials can be plastically deformed in a simple way and with reduced means. Finally, there is the advantage of not using very expensive alloys which, although of higher conductivity, have a higher mechanical resistance (modulus of elasticity or shear modulus), for example, than copper or economical copper alloys.

[0044] Alternatively or additionally, the second material is chosen from the group comprising: steel, spring steel. This provides the advantage of a particularly economical production of the connector. Steel or spring steel are deformable metallic materials having a high shear modulus or a high modulus of elasticity and which are economical. A second segment of the contact strip can thus comprise the second proposed material so that the contact strip of the connector for a very reduced dimensioning will have, for example, material thicknesses of approximately 0.4 mm or approximately 0.3 mm or approximately 0.2 mm or even approximately 0.15 mm or approximately 0.1 mm which will be mechanically reinforced or supported in order to have a permanently high normal contact force and not to have relaxation which would negatively influence the normal contact force of the contact strip.When using the second material, for example, also in the case of an optional latching tab or in the front part of the contact housing, the advantage is a high primary holding force, for example exerted by the latching tab against the extraction of a connector housing from the contact chamber or a high resistance to deformation of the contact housing in the event of poor engagement of the opposing contact element. Brief description of the drawings

[0045] The present invention will be described hereinafter in more detail with the aid of connector embodiments, shown in the accompanying drawings in which:

[0046] [Fig. 1] diagram of a stamping plate with folding lines for an embodiment of a connector,

[0047] [Fig.2a] schematic longitudinal section of the connector made from the plate stamping of [Fig.l],

[0048] [Fig.2b] schematic section of a connector made from the plate stamping of [Fig.l],

[0049] [Fig.2c] partial schematic perspective view of the connector of figures 2a, 2b.

[0050] DESCRIPTION OF EMBODIMENTS OF THE INVENTION

[0051] [Fig.l] shows, by way of example, a schematic representation of a stamping plate 7 with folding lines 50, 52 for an embodiment of a connector 1 (see figures 2a, 2b, 2c). After its production by various bending steps, this connector is in the form of a contact socket also called a female contact.

[0052] On the stamping plate 70 shown, the various components of the connector 1 are already cut, stamped and partly already folded or printed.

[0053] The connector 1 (see the views of FIGS. 2a, 2b, 2c) comprises a contact housing 2 oriented in an axial direction (A) for receiving an opposing contact element 30 as well as a contact strip 3; the contact housing 2 has a first wall 21 and a second wall 22 opposite each other with respect to the radial direction (R) transverse to the axial direction (A). The contact strip 3 is between the first wall 21 and the second wall 22 in the contact housing 2, with respect to the radial direction (R); the contact housing 2 is made mainly of a first material M1 for a first segment 4 and mainly of a second material M2 for a second segment 5 adjacent to the first segment 4. The second segment 5 is provided between the first segment 4 and the first wall 21; it overlaps the first segment 4 and the first wall 21.The shear modulus of the second material M2 is at least 1.5 times the shear modulus of the first material ML. In this embodiment, the modulus of elasticity of the second material M2 is at least 1.5 times the modulus of elasticity of the first material ML. In this embodiment, the first material M1 is copper or a more economical copper alloy and the second material M2 is steel. The contact housing 2 and the contact strip 3 are made of a single sheet 6 in the form of a pressed-bent part. The first material M1 has a first thickness (d1) and the second material M2 has a second thickness (d2). The first thickness (d1) and the second thickness (d2) can be equal as shown here. But these thicknesses can also be different.

[0054] The contact housing 2 of this exemplary embodiment is closed like a box. Here, for example, it has a rectangular cross-section. The contact housing 2 here, for example, has a first wall 21 which is a kind of cover of the contact housing 2, for example, a kind of inner cover. The contact housing 2 also has a second wall 22 which is here a kind of bottom of the contact housing 2. In this exemplary embodiment, the second wall 22 is pre-bent radially inwards and has a contact point 9. In this exemplary embodiment, it thus has, in addition to the function of stabilizing the contact housing 2, the function of being a (further) contact strip. The contact housing 2 of this exemplary embodiment has a third wall 23 and a fourth wall 24; the third wall 23 is a kind of first side wall and the fourth wall 24 is a kind of second side wall.The contact housing 2 in the finished state of manufacture (see, for example, figures 2b, 2c) is produced here with a . closed periphery in the direction of circulation (U) around the axial direction (A).

[0055] In principle, other sections of the contact housing 2 and possible shapes could also be available in which the contact housing 2 is partially or even widely open, i.e. with an unclosed periphery; these are, for example, contact housing side walls 23, 24 which are perforated or an perforated contact housing bottom (second wall 22) or an perforated contact housing cover (first wall 21).

[0056] According to figures 1, 2a, 2b, 2c the contact strip 3 has a printed contact point 9. In the embodiment shown, the contact point 9 is in the first segment 4. It projects radially inwards so that an opposite contact element 30, engaged, will be in certain electrical and mechanical contact with a defined point.

[0057] The second segment 5 is in mechanical contact at a first point P1 with the first wall 21. This mechanical contact can open here, for example, without destruction, that is to say that the second segment 5 is applied against the first wall 21 without being connected to it, for example, by a connection by the shape. The second segment 5 is in mechanical contact at a second point P2 with the first segment 4. This mechanical contact is here, for example, detachable without destruction; this means that the second segment 5 is applied against the first segment 4 without being connected to it, for example, by a connection by the material. The second point P2 is, in particular, not a point on the junction edge between the first material M1 and the second material M2. For example, it is here closer to the free end of the second segment 5.In this way, the second segment 5 is sandwiched between the first segment 4 and the first wall 21 by being integrated therein and it can bear at the first point PI against the first wall 21 and transmit the bearing force via the second point P2 to the first segment 4 of the contact strip 3.

[0058] Preferably, the second point P2 is at most 2 mm, preferably at most 1 mm and particularly preferably at most 0.5 mm from the contact point 9 of the first segment 4. This distance is measured in the axial direction A; it is thus a lateral distance. In this way, the contact force of the second segment 5 acts on the contact point 9 of the first segment 4 preferentially for large parts in the radial direction towards the inside, i.e. on an opposite contact element 30, which is plugged in.

[0059] In the present embodiment, the connector 1 has, only by way of example, in addition, a connection area 7 for fixing an electrical line 8; the connection area 7 is adjacent to the contact housing 2 or to the contact strip 3; the connection area 7 is mainly made of the first material M1; the connection area 7 with the contact housing 2 and the contact strip 3 are made from a single sheet 6 in the form of a stamped-folded part.

[0060] The electrical line 8 here comprises, by way of example, insulation 81 which surrounds an electrical conductor 82. The electrical line 8 of this exemplary embodiment can be brought into electrical and mechanical contact, i.e., can be connected or fixed to the connector 1 in the connection area 7 using the insulation crimping tabs 72 and the conductor crimping tabs 71 with the connector 1 or can be connected to it or fixed to the connector 1. There are also other possibilities for bringing into electrical and mechanical contact, for example, by a connection, by welding, brazing, by cutting and clamping, etc. It is not essential to provide a connection area 7.

[0061] In this exemplary embodiment, the connector 1 is produced solely by way of example, as a latching tab contact. For this purpose, the connector 1 comprises a latching tab 10 projecting outwards (here an inclined tab) and which can move inwards in an elastically reversible manner. The latching tab 10 is here, by way of example, mainly formed from a second material M2. The latching tab 10 is here, by way of example, installed or produced in an element radially outside the first wall 21 or it is produced in a latching plate 21 by being released by stamping. The latching plate 25 according to another embodiment, is also adjacent to the second wall 22, the third wall 23 or the fourth wall 24 (each time beyond this wall 22, 23, 24).

[0062] The hooking plate 25 is part of the stamping plate 70. It is bent during folding, for example, along a folding line 50, transversely to the axial direction A, over 180° (see the arrow bearing the reference 200 in [Fig.l]). It thus arrives in its place, radially outside the first wall 21 (see [Fig.l], 2a). The hooking plate 25 can be considered as belonging to the contact housing 2. The connector 1 may also not have a hooking plate 25 or be produced without a hooking tab 10. It is also possible to provide several hooking tabs 10. The hooking tab 10 ensures the primary hooking of the connector 1, for example, in a contact chamber not shown here of a connector, the hooking tab 10 coming to grip, for example, behind an undercut part of the contact chamber.This production of the hooking tab 10 mainly in the second material M2 makes it possible to achieve greater primary holding forces, i.e. release forces for an otherwise identical dimensioning as would be the case with a production with the first material.

[0063] This avoids other embodiments of the attachment strip 10. In other embodiments, there would be, for example, a recess in the plate hooking plate 25 or in one of the walls 21, 22, 23, 24 with a recess into which an elastic element of a contact chamber can penetrate and thus hook the connector 1 in a contact chamber of a connector housing, in particular to ensure the primary hooking; instead of a recess, it is possible to have only an undercut portion. In such an embodiment, it is also advantageous for the recess (or the undercut portion) to be provided in or on the hooking plate 25 or in particular made mainly in the second material M2 hooking 25 or in particular made mainly in the second material M2. This allows, for otherwise identical dimensions, better mechanical stability than if such an undercut were in an element made of the first material M1 and having the same thickness or even strength.

[0064] [Fig. 1] shows how the connector 1 can be produced, by way of example, after the sheet metal 6 resulting from a first step has already been drawn out by stamping and according to which, in a further step, the above-described elements of the connector 1 have already been drawn out from the sheet metal 6 and also, furthermore, solely by way of example, the contact strip 3 or at least its first segment 4 have been brought into an elastic shape and the contact point 9 has been printed in the sheet metal 6. In [Fig. 1], the stamping plate 7 is still practically in the 2-dimensional shape of the sheet metal 6. The sheet metal 6 or the metal strip of the stamping plate 70 has two areas made of different materials, the first material M1 and the second material M2 secured to each other (in a manner that cannot be separated without destruction); This is, for example, a casting process or a welding process or a printing process or a gluing process.

[0065] In another step 200 of this embodiment, the second segment 4 released by stamping is folded back (see the arrow); this is the folding line 50 oriented transversely to the axial direction (A) and which is located substantially on the junction edge between the two materials M1, M2. The folding is carried out over approximately 180° so that the stamped shape or the element of the second segment 5 of the contact strip 3 comes into contact with the stamped shape of the first segment 4 of the contact strip 3. In addition, in this exemplary embodiment, the hooking plate 25 with the hooking tab 10 comes into proximity with the stamped shape of the first wall 21. In another method step, given by way of example, the contact housing 2 is produced by placing the four walls 21, 22, 23, 24 along the folding lines 52 which are substantially or precisely parallel to the axial direction A to form a box or folded to obtain a box.The folding is done in this way, so that the second segment 5 of the contact strip 3 arrives between the first segment 4 and the first wall 21, overlapping the first segment 4 and the first wall 21 at least partially and preferably over more than 50% of its length and in a manner. very preferentially, over its entire length. Thus, in this sequence of steps given solely by way of example, the second segment 5 is sandwiched between the first segment 4 and the first wall 21. It thus makes it possible to exert an elastic force in the radial direction (R) on the first segment 5 by itself bearing against the contact box 2. During the described shaping of the contact housing 2, the hooking plate 25 also arrives with the hooking tab 10 in its final position, from the first wall 21 here radially to the outside. The hooking plate 25 can be, for example, produced in the form of another cover of the contact housing 2, here by way of example, in the form of an outer cover which is radially beyond the first wall 21 functioning as an inner cover.The hooking tab 10 can be produced already before step 200 of the first bending from the support plate 70 or from the hooking plate 25.

[0066] It is also possible to have other stamping patterns or other series of bends consisting first of all in bending the contact housing 2 before, then the hooking plate 25 is folded with the hooking tab 10 along the bending line 50 at an angle of approximately 180°.

[0067] Furthermore, the choice of materials described, by way of example above, does not constitute an essential feature of the invention; other pairs of materials can, in principle, be envisaged as long as the second material M2 has a modulus of elasticity at least 1.5 times as large as that of the first material M1 or as long as the second material M2 has a shear modulus which is at least 1.5 times as large as that of the first material M1. The first material M1 can, for example, be chosen from the following group: copper, copper alloy, aluminum, aluminum alloy, silver, silver alloy, gold, gold alloy. Alternatively or additionally, the second material M2 is, for example, chosen from the group comprising: steel, spring steel, iron.

[0068] According to another characteristic, the connector 1 comprises at least one coding tab or at least one engagement ramp (for example, at the front end, 90 facing the opposite contact element 30). Such elements are preferably formed in the second material M2, because the latter is mechanically stronger.

[0069] Furthermore, it is possible, for example, in another embodiment, to provide that a part of the contact housing 2, in particular the front part of the contact housing 2 facing the opposite contact element 30, is made of this second material M2 (rear part 92 of the contact housing 2 here facing the connection area). These embodiments are possible separately or in combination with other stamping patterns of the stamping plate 70 (see [Fig. 1]). The contact housing 2 can, in this way, always be mainly made of the first material M1, but at the locations subject to high mechanical stress, it must (in part) have the second subject M2.

[0070] According to another characteristic, the second segment 5 is made partly from the first material M1. This may concern, for example, the bending or folding zone 11 in which the first segment 4 is connected to the second segment 5. Such a folding zone 11 may be, for example, in a range of up to 3 mm, preferably up to a maximum of 2 mm and particularly preferably up to a maximum of 1 mm and even more preferably up to 0.5 mm, for example 0.1 mm, 0.2 mm, 0.3 mm or 0.5 mm around the junction edge between the two materials M1, M2. This makes it possible to fold the second segment in a particularly simple manner.

[0071] Alternatively or additionally, the first segment 4 or the contact housing 2 (preferably on the front part 90) can be made partially with the second material M2, in particular in the bending zone 11. This makes it possible to produce a more robust front end of the connector 2 to protect it against forced insertion of the connector 1 into the contact chamber or incorrect insertion of the opposing contact element 30 or to produce a robust contact strip 3 resistant to incorrect insertion.

[0072] In the present exemplary embodiment, for reasons of clarity of the drawing, a connector 1 is shown whose folding along the folding line 50 or the folding line 50 is made on the junction edge between the two materials M1, M2.

[0073] It is also possible to have a first thickness (dl) of the first material Ml which differs from the second thickness (d2) of the second material M2. Thus, for example, the first thickness (dl) of the first material Ml for the contact housing 2 and the first segment 4 of the contact strip 3 can be less than the second thickness (d2) of the second material M2. This provides the advantage of saving on the first material Ml, which is generally the most expensive because the first segment 4 is mechanically stabilized by the second segment 5. Also, in the opposite case, for example, the first thickness (dl) is approximately double the second thickness (d2), for example, the first thickness (dl) is equal to 0.3 mm and the second thickness (d2) is equal to 0.15 mm. This makes it possible to produce a particularly thin connector 1 having high mechanical strength and with less relaxation of the normal contact forces.In the present embodiment, the first thickness (dl) and the second thickness (d2) are identical for reasons of readability of the figures; technically this allows particularly simple handling, for example, of the guiding of the sheet metal 6.

[0074] NOMENCLATURE OF MAIN ELEMENTS

[0075] 1 Connector

[0076] 3 Contact blade

[0077] 4 First segment of the contact blade

[0078] 5 Second segment of the contact blade

[0079] 6 Sheet metal

[0080] 7 Connection zone

[0081] 8 Power line

[0082] 9 Point of contact

[0083] 10 Hanging tab

[0084] 11 Folding zone

[0085] 21 First wall

[0086] 22 Second wall

[0087] 23 Third wall

[0088] 24 Fourth wall

[0089] 25 Hanging plate

[0090] 30 Opposite contact element

[0091] 50 Fold line

[0092] 52 Fold line

[0093] 70 Stamping plate

[0094] 71 Conductor crimping tab

[0095] 72 Insulation crimping tab

[0096] 90 Front end of contact housing

[0097] 92 Rear end of the contact housing

[0098] A Axial direction of the contact housing

[0099] dl First thickness

[0100] d2 Second thickness

[0101] Ml First matter

[0102] M2 Second subject

[0103] P2 Second point of contact

[0104] R Radial direction transverse to the axial direction

[0105] U Peripheral Direction

Claims

Claims

1. Connector comprising: - a contact housing (2) oriented in an axial direction (A) for receiving an opposing contact element (30), - a contact strip (3), * the contact housing (2) having a first wall (21) and a second wall (22) opposite with respect to the radial direction (R), transversely to the axial direction (A), * the contact strip (3) is provided in the contact housing (2) between the first wall (21) and the second wall (22) in the radial direction (R), * the contact housing (2) is made mainly of a first material (Ml), * the contact strip (3) is made of a first material (Ml) in a first segment (4) and mainly of a second material (2) in a second segment (5) adjacent to the first segment (4), * the second segment (5) provided between the first segment (4) and the first wall (21) overlaps the first segment (4) and the first wall (21),* the shear modulus of the second material (M2) is at least 1.5 times the shear modulus of the first material (Ml), or the modulus of elasticity of the second material (M2) is at least 1.5 times the modulus of elasticity of the first material (Ml), * the contact housing (2) and the contact strip (3) are produced in the form of a pressed part folded from a single sheet (6).,

2. Connector according to claim 1, the connector (1) being designed as a contact socket.

3. Connector according to one of the preceding claims, wherein - the connector (1) has a connection area (7) for being fixed to an electrical line (8), - the connection area (7) is adjacent to the contact housing (2) or to the contact strip (3), * the connection area (7) is made mainly of the first material (Ml), and - the connection area (7) is produced with the contact housing (2) and the contact strip (3) in a single sheet metal (6) as a pressed-bent part.

4. Connector according to one of the preceding claims, in which * the second segment (5) is in mechanical contact at a first point (PI) with the first wall (21), in particular a detachable contact without destruction, * the second segment (5) in a second point (P2) which in particular is not located on the junction edge between the first segment (4) and the second segment (5) is in mechanical contact, in particular opening without destruction, with the first segment (4).

5. Connector according to one of the preceding claims, in which the contact strip (3) comprises a contact point (9), printed, in particular in its first segment (4).

6. Connector according to claim 5, wherein the second point (P2) is at most 2 mm, preferably at most 1 mm, from the contact point (9).

7. Connector according to one of the preceding claims, in which a part of the contact housing (2) or a part of the first segment (4), in particular a front part (90) of the contact housing (2) or of the first segment (4) facing the opposite contact element (30) is made of the second material (M2).

8. Connector according to one of the preceding claims, in which the contact housing (2) is peripherally closed in a direction of circulation (U) around the axial direction (A).

9. Connector according to one of the preceding claims, in which the connector (1) comprises a hooking tab (10) projecting outwards and which can be moved inwards in an elastically reversible manner.

10. Connector according to one of the preceding claims, in which the first material (Ml) is chosen from the group comprising: copper, copper alloy, aluminum, aluminum alloy or the second material (M2) is chosen from the group comprising: steel, spring steel.

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