Electrical contact for making an electrical connection with an electrical conductor

Abstract

The present invention relates to an electrical contact (10) comprising: a contact portion (20), a connection portion (22) and a transition portion (24). The connection portion (22) comprises a contact surface (38), in particular a planar contact surface (38), configured for electrical connection with an electrical conductor. The transition portion (24) is arranged between the contact surface (38) and the connection portion (22) along a longitudinal direction (100) of the electrical contact (10). At least one first side wall projects from the contact surface (38) and extends at least along the transition portion (24) relative to the longitudinal direction (100) of the electrical contact (10). Figure for abstract: Fig. 2

Description

Title of the invention: Electrical contact for making an electrical connection with an electrical conductor

[0001] The present invention relates to an electrical contact for making an electrical connection with an electrical conductor, such as a connector cable or a bus bar. The present invention also relates to a connection assembly comprising an electrical contact and an electrical conductor.

[0002] In most applications, it is desirable to provide a stable and durable electrical connection between the electrical contact and a connector cable or bus bar. Ultrasonic welding, electric resistance welding, or induction welding are known methods for welding an electrical contact to a connector cable or bus bar. Ultrasonic welding is a welding process using high-frequency vibrational energy. It is a solid-state welding process in that the materials to be welded do not undergo melting, unlike electric resistance welding. Electric resistance welding is performed under pressure and with a high electric current. With induction welding, heat is electromagnetically induced into the electrical contact.

[0003] In the automotive industry for example, especially for the charging socket of an electric vehicle, it is desirable to provide an electrical contact with a high current transmission capacity. Poor current transmission capacity could cause undesirable heating of the electrical contact.

[0004] An electrical contact known from the state of the art is illustrated in [Fig. 1]. The electrical contact 1 of [Fig.l] comprises a contact portion 2, a connection portion 3 and a transition portion 4 arranged between the contact portion 2 and the connection portion 3 along a longitudinal direction 100 of the electrical contact 1. The connection portion 3 comprises a planar contact surface 5. The end 6 of an electrical conductor 7 is welded by means of ultrasonic welding to the planar contact surface 5. The sectional view (A), transverse to the longitudinal direction 100, shows that the cross-sectional area of ​​the electrical contact 1 at this location is equivalent to the sum of the section A1 of the end 6 of the electrical conductor 7 and the section A2 of the connection portion 3.At the boundary between the connection portion 3 and the transition portion 4, the cross-section of the electrical contact 1 is only equal to the cross-section A2 of the connection portion 3, as shown by the sectional view (B) transverse to the longitudinal direction 100. In the example of [Fig.l], the cross-section is reduced by almost 50% between the sectional view (A) and the sectional view (B).

[0005] Too small a cross-section at the transition portion is undesirable because this might not allow satisfactory transmission of current, especially high voltage direct current.

[0006] An object of the present invention is to provide an electrical contact for an electrical connection which is improved over the prior art.

[0007] The object of the present invention is achieved by means of an electrical contact comprising: a contact portion, a connection portion, the connection portion comprising a planar contact surface configured for electrical connection with an electrical conductor, and a transition portion, the transition portion being arranged between the planar contact surface and the contact portion along a longitudinal direction of the electrical contact. At least one first side wall projects from the planar contact surface and extends at least along the transition portion relative to the longitudinal direction of the electrical contact.

[0008] The feature of the side wall makes it possible to increase the cross-section of the transition portion. Increasing the cross-section makes it possible to reduce the electrical resistance. Decreasing the resistance can prevent heating of the electrical contact when an electric current passes through it. The transition portion is thus more suitable for the passage of a strong electric current.

[0009] The transition portion is defined as a portion that is adjacent to the contact surface. In particular, the contact surface and the transition portion are not superimposed, even partially, on each other. Only the contact surface of the connection portion may be configured to be in surface contact with an electrical conductor. In particular, the transition portion is not intended to receive an electrical conductor. The transition portion may be configured so as not to be in surface contact with an electrical conductor when the electrical conductor is electrically connected to the electrical contact.

[0010] Increasing the cross-sectional area at the transition portion is particularly advantageous because the electrical conductor would not contribute to the cross-sectional area at this location since the transition portion is not configured to receive the electrical conductor.

[0011] The increase in the cross-section at the transition portion makes it possible to advantageously reduce the cross-section at the connection portion, given that at the connection portion the cross-section of the electrical conductor contributes to the total cross-section. The possible reduction in the cross-section of the connection portion makes it possible in particular to reduce the thickness of the connection portion at the planar contact surface. A thinned planar contact surface is for example advantageous to facilitate certain welding processes and / or to save material.

[0012] In particular, the contact surface of the connection portion is limited to a flat surface. A flat surface is a surface such that a straight line passing through two of its points is entirely contained therein.

[0013] The side wall may be connected by material bonding to the transition portion. The side wall may project inclinedly relative to the planar contact surface, in particular with an inclination of between 45° and 135°, more particularly with an inclination of between 80° and 95°. The side wall may project perpendicularly to the planar contact surface, i.e. with an inclination of 90°. Thus, the side wall may be parallel to a lateral side of a bus bar for example. This may facilitate welding or bonding between the parallel surfaces of the side wall and a lateral side of the bus bar.

[0014] In particular, the electrical contact is configured for electrical connection with a bus bar, comprising an insulating or non-insulating coating, by means of a welding process.

[0015] The connecting portion may include an opposing surface that is geometrically opposite the planar contact surface. The opposing surface may be planar. The opposing surface may be parallel to the planar contact surface. Alternatively, the opposing surface may be a curved surface.

[0016] According to one embodiment, the side wall may extend from the connection portion to the transition portion, in particular from a distal end of the connection portion to the transition portion. This may make it possible to improve the mechanical strength of the electrical connector.

[0017] According to one embodiment, the electrical contact may comprise a second side wall, and the two side walls may be arranged opposite each other respectively along the longitudinal direction of the electrical contact.

[0018] The presence of a second side wall makes it possible to further increase the cross-section of the transition portion.

[0019] Further, the two side walls may be used to guide an inserted conductive cable or bus bar to be welded when the conductive cable or bus bar is inserted between the two side walls.

[0020] The two side walls may be symmetrical to each other along the longitudinal direction. The electrical contact may be easily formed by a cold forming process.

[0021] At least one cross-section of the connection portion or the transition portion, or both, may have a "U" shape. The "U" shape refers to the shape of the letter "U" according to the Latin alphabet, and the central portion of the "U" shape is flat because it corresponds to the flat contact surface. This particular geometry allows to improve the mechanical strength of the electrical contact, which is, for example, particularly advantageous for better withstanding the vibrations induced by ultrasonic welding. Ultrasonic welding can indeed involve frequencies between 20 and 70 kHz that generate strong mechanical vibrations in the electrical contact.

[0022] According to one embodiment, the largest cross-section of the electrical contact at the connection portion is equal to or less than the smallest cross-section of the transition portion. In particular, the largest cross-section of the electrical contact at the connection portion is strictly less than the smallest cross-section of the transition portion. It is thus possible to thin the electrical contact at the connection portion.

[0023] At least one portion of the transition portion may protrude relative to the contact portion and the connection portion. The protruding portion(s) may respectively form a support or a locking surface on which a connector housing may abut, for example, in particular in the longitudinal direction. The protruding portion(s) may make it possible to hold the connection device between a housing and a housing cover.

[0024] The transition portion may comprise a first portion. The first portion may have a solid, circular disc-shaped cross-section. The first portion may have a constant cross-section. The first portion may provide a surface suitable for temperature measurement. The temperature measurement may be performed by means of a temperature sensor. It is indeed sometimes necessary to monitor the temperature of an electrical contact, in particular when it is an electrical contact used for charging electric vehicles in a charging base. Alternatively or in combination, the first portion may provide a surface suitable for maintaining the electrical contact during the ultrasonic welding process.

[0025] According to one embodiment, the planar contact surface may be configured to make an electrical connection with an electrical conductor by means of: laser welding, ultrasonic welding, electric resistance welding, induction welding, or cold bonding with a conductive adhesive. The contact surface is particularly suitable for welding and bonding because it is planar. In particular, a planar contact surface is particularly desirable for ultrasonic welding.

[0026] The electrical contact may be configured to make an electrical connection without a crimping process.

[0027] According to one embodiment, the electrical contact may comprise a transition surface and at least a first locking surface, the first locking surface being substantially transverse to the planar contact surface, and the transition connecting the first locking surface to the planar contact surface.

[0028] The transition surface is bordered by the at least one side wall, in particular by the two side walls. The transition surface may be a planar surface. The transition surface may be formed by a downward slope from the transition portion to the planar contact surface. Alternatively, the transition surface may be a curved surface, or at least partially curved. The transition surface may be convex. The transition surface may be concave. This saves material.

[0029] The transition portion may comprise a second portion, the second portion being disposed between the first portion of the transition portion and the connecting portion. The second portion of the transition portion may comprise the transition surface.

[0030] The locking surface may be formed by a projecting portion of the transition portion, in particular by a projecting portion of the first portion of the transition portion. The locking surface may be perpendicular to the planar contact surface.

[0031] According to one embodiment, the planar contact surface may be offset parallel to a longitudinal central axis of the contact portion. This makes it possible to align a central longitudinal axis of an electrical conductor connected to the contact surface with the longitudinal central axis of the contact portion. Aligning the central longitudinal axis of the electrical conductor with that of the contact portion makes it possible to obtain a more compact electrical contact. This alignment may make it possible to reduce the size of a cavity of a sealing element in which the electrical conductor can be received.

[0032] According to one embodiment, the height of the side wall from the planar contact surface may vary at least partially in an increasing manner in a direction from the connection portion towards the contact portion. Compared with a side wall having a constant height, this makes it possible to reduce the height of the side wall and thus save material for forming the electrical contact.

[0033] Alternatively, the height of the side wall from the planar contact surface may be constant in a direction from the connection area to the contact area. This provides an increase in mechanical strength in a homogeneous manner along the longitudinal direction.

[0034] The contact portion may be configured to mate with a mating electrical connector. The contact portion may be male or female. A male contact portion may be a pin. A female contact portion may include a hollow tubular housing for receiving a mating male connector. In one embodiment, the contact portion may be a solid contact pin. The contact pin may have a cylindrical shape. The contact pin may have one or more metal coatings. The contact pin may have multiple metal coatings of identical composition. Alternatively, the contact pin may have multiple metal coatings whose composition is different from one another. For example, the contact pin may have a silver coating and a nickel undercoat. The contact pin may have a galvanic coating comprising silver, gold, or tin. The end of the contact portion may be provided with a cap. The cap protects the end of the contact pin and reduces hazards when touched. The cap thus provides finger protection, more commonly referred to as "touch-safe" in English. The cap may be detachably arranged on the contact portion.The cap may be made from a dielectric material, for example a plastic material.

[0035] Alternatively, the contact portion may be a contact socket. Unlike the solid contact pin which has a solid structure, the contact socket has a hollow structure. The hollow structure of the contact socket is adapted to receive an electrical conductor.

[0036] According to one embodiment, the electrical contact may be formed integrally in one piece. This avoids assembly steps. The electrical connector may be formed from an electrically conductive material. The electrical connector may be formed from a metallic material. The electrical connector may be formed by a cold forming process. The electrical contact may be made of copper or a copper alloy, in particular a copper alloy with a high copper content. The use of copper is advantageous due to its very good electrical conductivity. The electrical contact may be made of aluminum or iron.

[0037] The object of the present invention is also achieved by a connection assembly comprising an electrical contact according to at least one of the embodiments described above and an electrical conductor, in particular a conductive cable or a bus bar, in which the electrical conductor is welded or glued to the flat contact surface.

[0038] In particular, the conductive cable or bus bar may be solely welded or bonded to the planar contact surface. The connection assembly may be characterized by an absence of welding between the side wall(s) and the conductive cable or bus bar. This embodiment is particularly suitable for ultrasonic welding between the conductive cable or bus bar and the electrical contact. The conductive cable or bus bar may be arranged in the connection portion such that each side wall is spaced from the conductive cable or bus bar. bus. The greatest distance between the first sidewall and the second sidewall may be at least 5% and at most 30% greater than the transverse dimension of the conductor cable or bus bar in a plane parallel to the planar contact surface. The greatest distance between the first sidewall and the second sidewall may be greater than the diameter of the first portion of the transition portion. The first portion may be a solid cylindrical portion.

[0039] Alternatively, the conductive cable or bus bar may be welded or bonded to both the planar contact surface and at least one side wall, in particular both side walls. This advantageously increases the contact surface between the conductive cable or bus bar and the electrical contact. This embodiment is particularly suitable for electrical resistance welding between the conductive cable or bus bar and the electrical contact.

[0040] In the connection assembly, a longitudinal central axis of the conductive cable or bus bar may be aligned with a longitudinal central axis of the contact portion. This advantageously makes it possible to reduce the size of the connection assembly. This alignment may make it possible to reduce the size of a cavity of a sealing element in which the conductive cable or bus bar can be received.

[0041] A bus bar may be a substantially rigid bar-shaped metallic material. The bus bar may have a solid cross-section. The bus bar may include at least one planar surface. The bus bar may have a rectangular cross-section. Alternatively, the bus bar may have a cylindrical shape. The bus bar may have a disc-shaped cross-section.

[0042] According to one embodiment, the connection assembly may comprise the electrical contact and a bus bar, in particular a bus bar comprising at least one flat face, more in particular a bus bar of rectangular cross-section.

[0043] A conductive cable may comprise a plurality of conductive metal strands, for example copper. The conductive cable may have a substantially circular cross-section before welding. The portion of the conductive cable welded to the planar contact surface may have a rectangular cross-section.

[0044] A cross-section of the transition portion corresponds to a surface of the transition portion in a plane perpendicular to the longitudinal direction of the electrical contact.

[0045] A cross-section of the connection portion corresponds to a surface of the connection portion in a plane perpendicular to the longitudinal direction of the electrical contact.

[0046] A cross-section of the contact portion corresponds to a surface of the contact portion in a plane perpendicular to the longitudinal direction of the electrical contact.

[0047] According to another aspect of the present invention, the object of the present invention can be achieved by means of an electrical contact comprising: a contact portion, a connection portion, the connection portion comprising a contact surface configured for electrical connection with an electrical conductor, and a transition portion, the transition portion being disposed between the contact surface and the contact portion along a longitudinal direction of the electrical contact. At least one first side wall projects from the contact surface and extends at least along the transition portion relative to the longitudinal direction of the electrical contact.

[0048] According to one embodiment of this aspect, the contact surface may be a planar surface. A planar contact surface is adapted to make an electrical connection with a conductive cable, which may be flattened or pressed onto said planar contact surface. A planar contact surface is particularly adapted to make an electrical connection with a bus bar having at least one planar face.

[0049] Alternatively, according to another embodiment of this aspect, the contact surface may be a curved surface. A curved contact surface is suitable for making an electrical connection with a conductive cable. A curved contact surface is particularly suitable for making an electrical connection with a cylindrical bus bar, ie having a disc-shaped cross-section.

[0050] According to another aspect of the present invention, the object of the present invention can be achieved by means of a connection assembly comprising a bus bar of cylindrical cross-section and an electrical contact. The electrical contact can comprise: a contact portion, a connection portion, the connection portion comprising a curved contact surface and a transition portion, the transition portion being arranged between the curved contact surface and the contact portion along a longitudinal direction of the electrical contact. At least one first side wall can protrude from the curved contact surface and extend at least along the transition portion relative to the longitudinal direction of the electrical contact. An electrical connection can be made between the electrical contact and the bus bar at the curved contact surface.

[0051] The invention and its advantages will be explained in more detail hereinafter by means of exemplary embodiments and with reference to the following accompanying figures, in which:

[0052] [Fig-1] schematically illustrates an electrical contact according to the state of the art; [Fig.2] schematically illustrates an electrical contact according to a first embodiment; [Fig.3] schematically illustrates a connection assembly according to the first embodiment; [Fig.4] schematically illustrates an electrical contact according to a second embodiment; [Fig.5] schematically illustrates an electrical contact according to a third embodiment; [Fig.6] schematically illustrates an electrical contact according to a fourth embodiment; [Fig.7] schematically illustrates an electrical contact according to a fifth embodiment; [Fig.8] schematically illustrates a partial and sectional view of a connector housing comprising two electrical connectors according to the first embodiment.

[0053] [Fig.2] schematically illustrates an electrical contact 10 according to a first embodiment. The electrical contact 10 is manufactured from an electrically conductive material. The electrical contact 10 may be formed integrally in a single metal part. The electrical contact 10 comprises three portions along a longitudinal direction 100: a contact portion 20, a connection portion 22 and a transition portion 24. The transition portion 24 is arranged between the contact portion 20 and the connection portion 22 along a longitudinal direction 100.

[0054] The contact portion 20 is pluggable to a mating electrical contact (not shown), in particular along the longitudinal direction 100. In the illustrated example, the contact portion 20 is a contact pin 26, more commonly called a “contact pin” in English. The contact pin 26 has a substantially cylindrical shape and a substantially circular cross-section. The contact pin 26 has a longitudinal central axis 110. The longitudinal central axis 110 is parallel to the longitudinal direction 100. The contact pin 26 has a solid structure.

[0055] The contact pin 26 extends between a first end 30 and a second end 32 opposite the first end 30 with respect to the longitudinal direction 100. The first end 30 is connected to the transition portion 24. The second end 32 may be provided with a cap 28, as illustrated in the example of [Fig.2],

[0056] The contact pin 26 may comprise a circumferential shoulder 34. In particular, the contact pin 26 may comprise a single circumferential shoulder 34 along its length. The presence of the circumferential shoulder 34 forms a segment 36 comprised between the first end 30 and the circumferential shoulder 34. A cross-section at the segment 36 is larger than a cross-section of the remainder of the contact pin 26. The segment 36 of the contact pin 26 is configured to receive a seal 12 (visible in [Fig. 3]), in particular a seal 12 of annular shape. The seal 12 may have an inner diameter approximately equal to the outer diameter of the segment 36. The seal 12 may be held by friction to the segment 36.

[0057] The contact portion 20 can be characterized by the absence of collars. A collar can be formed between two successive circumferential shoulders. For example, three successive collars are visible on the contact portion 2 of the electrical contact 1 according to the state of the art (cf. [Fig. 1]). The presence of a single circumferential shoulder 34 on the contact portion 20 advantageously allows reducing the length of the contact portion 20 while allowing a satisfactory maintenance of the seal 12. It is understood that the length of the contact portion is defined from the central longitudinal axis 110.

[0058] The connection portion 22 is configured to make an electrical connection, in particular an electrical connection and a mechanical connection, with an electrical conductor (visible in [Fig. 3]). The connection portion 22 comprises a contact surface 38. The contact surface 38 is configured for an electrical connection with an electrical conductor (visible in [Fig. 3]) by means of welding or gluing. The contact surface 38 is planar. The planar contact surface 38 may have a rectangular shape. The planar contact surface 38 may have an area of ​​between 5 square millimeters and 1000 square millimeters, in particular between 50 square millimeters and 250 square millimeters. The planar contact surface 38 serves as a support for welding or gluing with an electrical conductor. An electrical conductor, in particular a rigid bus bar, may be placed, preferably flat, on the planar contact surface 38.

[0059] When the electrical connection is made by an ultrasonic welding process, an active part of a sonotrode can be brought above the bus bar and send vibrations to effect welding of the bus bar with the electrical contact 10 at the level of the planar contact surface 38.

[0060] [Fig.3] illustrates a longitudinal sectional view of the electrical contact 10 and two cross-sectional view of the electrical contact 10. [Fig. 3] also shows an electrical conductor 7 whose end 6 is arranged on the flat contact surface 38 of the electrical contact 10. The electrical contact 10 and the electrical conductor 7 form a connection assembly. In the following, reference is made to Figures 2 and 3.

[0061] The connection portion 22 comprises a second surface 40, opposite the planar contact surface 38. In the example of [Fig. 2], the second surface 40 is a planar surface. The planar contact surface 38 and the second surface 40 are parallel to each other and to the longitudinal direction 100. The distance between the planar contact surface 38 and the second surface 40, in other words the thickness of the connection portion 22, is indicated by the reference sign 42 in Figures 2 and 3.

[0062] The transition portion 24 comprises a first portion 44 and a second portion 50.

[0063] The first portion 44 has a cylindrical shape defined by an outer circumferential wall 46 that extends between a first circular base 52 and a second circular base 54. The first portion 44 has a disc-shaped cross-section. In other words, the first portion 44 has a solid structure. The first portion 44 has a longitudinal central axis 120. The longitudinal central axis 120 of the first portion 44 is aligned with the longitudinal central axis 110 of the contact portion 20. The contact portion 20 is directly adjacent to the second circular base 54. The diameter of the first portion 44 is larger than the diameter of the contact pin 26. The diameter of the first portion 44 corresponds to the diameter of the first circular base 52, respectively to the diameter of the second circular base 54. The thickness of the first portion 44 corresponds to the distance between the first circular base 52 and the second circular base 54.The thickness of the first portion 44 may be adapted to allow temperature measurement on the circumferential wall 46 of the transition portion 24, in particular to monitor the temperature of the electrical contact 100 when an electric current passes through it. The thickness of the first portion 44 may be adapted to allow easier handling of the electrical contact 100 during the soldering or gluing process, or during assembly of the electrical contact 100 in a connector housing, or during both.

[0064] The second portion 50 (see [Fig.3]) connects the connection portion 22 to the first circular base 52 of the first portion 44. In the illustrated example, the first circular base 52 is perpendicular to the planar contact surface 38. In the illustrated example, the second portion has a solid structure, as illustrated by the sectional view of [Fig.3].

[0065] The second portion 50 comprises a transition surface 48. In the first embodiment, the transition surface 48 defines a slope 56, in particular a slope of 30° to 45° relative to the planar contact surface 38. The slope 56 may have a rounding 58, in particular towards the top of the slope 56 (visible in [Fig. 3]). The slope 56 is downward in a direction going from the transition portion 24 towards the planar contact surface 38. The transition surface 48 is inclined relative to the first circular base 52.

[0066] The second portion 44 projects relative to the first portion 50. The projecting surface(s) of the second portion 44 may respectively serve as a locking surface by forming a stop surface for a connector housing for example. A locking lance of a connector housing may abut the locking surface, which is further described in the following paragraph. A unintentional rotation, unintentional translational movement, or both, of the electrical contact 100 may be avoided. The first circular base 52 of the first portion 44 may include a first locking surface 60. The first locking surface 60 is a planar surface. The first locking surface 60 is oriented toward the planar contact surface 38. The transition surface 48 connects the first locking surface 60 to the planar contact surface 38.

[0067] The first circular base 52 of the first portion 44 may comprise a second locking surface 62 (visible in [Fig. 3]). The second locking surface 62 is a flat surface. The second locking surface 62 is oriented on the side of the second surface 40.

[0068] In another embodiment, the first circular base 52 of the transition portion 24 may have a single locking surface, or no locking surface.

[0069] The planar contact surface 38 is arranged parallel and offset relative to the longitudinal central axis 110 of the contact portion 20 and the longitudinal central axis 120 of the transition portion 24. Thus, the planar contact surface 38 is placed eccentrically relative to the first circular base 52 of the first portion 44. This offset of the planar contact surface 38 allows a longitudinal central axis 130 of an electrical conductor to be aligned with the longitudinal central axis 110 of the contact portion 20 and the longitudinal central axis 120 of the transition portion 24 (visible in [Fig. 3]). This arrangement makes it possible to reduce the size of the electrical contact 10.

[0070] Unlike the electrical contact 1 according to the state of the art (see [Fig.l]), the electrical contact 10 further comprises two side walls 64, 66. In the first embodiment, the side walls 64, 66 are symmetrical to each other. Thus, in the following, the description of the side wall 64 also applies to the side wall 66.

[0071] The side wall 64 projects from the planar contact surface 38. In particular, the side wall 64 projects perpendicular to the planar contact surface 38. The side wall 64 extends along the longitudinal direction 100 of the electrical contact 10 and is connected to the transition portion 24, in particular to the first circular base 52 of the first portion 44. The two side walls 64, 66 extend on either side of the second portion 50 of the transition portion 24. The transition surface 48 is thus at least partially bordered respectively by the side walls 64, 66. The side wall 64 has a free edge 70. The free edge 70 may be rounded.

[0072] At the connection portion 22, as illustrated by view (A) of [Fig. 3], the side wall 64 has a height 68 defined between the planar contact surface 38 and a free edge 70. In this example, the height 68 is defined along a per direction pendicular to the planar contact surface 38. The height 68 of the side wall 64 may be between 1 millimeter and 50 millimeters. The height 68 of the side wall 64 may be greater than the thickness 42 of the connection portion 22. Furthermore, at the connection portion 22, the side wall 64 has a thickness 69 defined in a direction parallel to the planar contact surface 38, as indicated by [Fig.2] and view (A) of [Fig.3]. The thickness 69 may be substantially the same as the thickness 42. Preferably, the thickness 69 may be greater than the thickness 42.

[0073] At the first portion 50, as illustrated by view (B) of [Fig.3], the side wall 64 has a height 67. The height 67 may be substantially equal to the height 68.

[0074] The first portion 50 has a thickness 43, as indicated by view (B) of [Fig. 3]. The thickness 43 of the second portion 50 may be substantially the same as the thickness 42 of the connection portion 22. Preferably, the thickness 43 of the second portion 50 may be greater than the thickness 42 of the connection portion 22. This makes it possible to provide an electrical contact having a connection portion 22 that is thinned relative to the second portion 50.

[0075] The two side walls 64, 66 are arranged opposite each other respectively along one side of the planar contact surface 38 along the longitudinal direction 100 of the electrical contact 10. At the connection portion 22, the presence of the two side walls 64, 66 provides a “U”-shaped cross-section. The “U” shape refers to the shape of the letter “U” according to the Latin alphabet, the central portion of the “U” shape of which is planar because it corresponds to the planar contact surface 38.

[0076] The sectional view (A) of [Fig. 3], transverse to the longitudinal direction 100, shows that the cross-section of the electrical contact 10 at this location is equivalent to the sum of the cross-section A1 of the end 6 of the electrical conductor 7 and the cross-section A3 of the connection portion 22. The cross-section A3 of the connection portion 22 comprises the cross-section of thickness 42 as well as the cross-section of each of the side walls 64, 66. The cross-section A3 of the electrical contact 10 is larger than the cross-section A2 of the electrical contact 1 according to the prior art illustrated by [Fig. 1] and which does not comprise side walls. Increasing the cross-section makes it possible to reduce the electrical resistance. Reducing the resistance can make it possible to avoid heating of the electrical contact when an electric current passes through it.

[0077] Advantageously, the side walls 64, 66 make it possible in particular to increase the cross-section of the electrical contact 10 in the transition portion 24, in particular at the level of the second portion 50 of the transition portion 24. The sectional view (B) of [Fig. 3] illustrates the second portion 50, which is a portion beyond which the end 6 of the electrical conductor 7 does not extend. At this location (see sectional view (B) of the Figure), the cross-section of the electrical contact 10 is defined only by the cross-section A4 of the second portion 50 of the transition portion 24.

[0078] The cross-section A4 of the electrical contact 10 is larger than the cross-section A2 of the electrical contact 1 according to the state of the art illustrated by [Fig.l] and which does not include side walls.

[0079] The cross-section A4 of the transition portion 24 may be substantially equal to the cross-section A3 of the connection portion 22. Preferably, the cross-section A4 of the transition portion 24 is greater, in particular strictly greater, than the cross-section A3 of the connection portion 22.

[0080] In particular, the sum of the cross sections A1 and A3 is at most two times larger, in particular at most 1.5 times larger, than the cross section A4. This prevents the cross section A4 of the electrical connector 10 at the transition portion 24 from being too small compared to the cross section (A1 + A3) at the connection portion 22, to which the cross section A1 of the electrical conductor 6 contributes.

[0081] Better continuity of the transmission of the electric current can be achieved, in particular at the second portion 50 of the transition portion 24, i.e. beyond which the end 6 of the electric conductor 7 does not extend, and therefore at which the electric conductor 7 does not contribute to the cross-section capable of conducting the current.

[0082] [Fig.4] schematically illustrates an electrical contact 80 according to a second embodiment. In the following, the elements bearing the same reference signs as those described previously will not be described again and reference is made to their description given in the preceding paragraphs.

[0083] The electrical contact 80 according to the second embodiment differs from the first embodiment in that a first locking surface 82 formed by a planar portion of the first circular base 52 of the transition portion 24 is larger than the first locking surface 60 according to the first embodiment. In the second embodiment, the inclination of the slope 56 of the transition surface 48 may be decreased compared to the first embodiment.

[0084] In the first embodiment, the height 68 of the side walls 64, 66 is constant along the planar contact surface 38. The electrical contact 80 according to the second embodiment differs from the first embodiment in that the height of each side wall 84, 86 from the planar contact surface 38 varies at least partially in an increasing manner in a direction going from the connection portion 22 towards the transition portion 24. In the second embodiment, a ramp 88 connects the planar contact surface 38 to each corresponding free edge 70. The volume of material required to manufacture the walls 84, 86 in the second embodiment is therefore less than the volume of material to manufacture the walls 64, 66 according to the first embodiment.

[0085] In the second embodiment, each of the side walls 84, 86 may be spaced a distance 90 from a distal end 92 of the connection portion 22 in the plane of the contact surface 38. The distal end 92 corresponds to the outermost free edge of the planar contact surface 38. A cross-section of the connection portion 22 at the distal end 92 may have a trapezoidal shape, as illustrated in [Fig. 4].

[0086] The electrical contact 80 according to the second embodiment makes it possible to reduce the quantity of material necessary to manufacture the electrical contact while ensuring satisfactory continuity of transmission because a cross-section A4 of the transition portion 24, i.e. at the level of the second portion 50 of the transition portion 24, is at least substantially the same as in the first embodiment at the level of the section represented by view (B) of [Fig.3].

[0087] [Fig.5] schematically illustrates an electrical contact 90 according to a third embodiment. In the following, the elements bearing the same reference signs as those described previously will not be described again and reference is made to their description given in the preceding paragraphs.

[0088] The electrical contact 90 according to the third embodiment differs respectively from the first embodiment and the second embodiment in that, in the connection portion 22, the second surface 92 opposite the planar contact surface 38 is a second convex surface 92. In other words, the second surface 92 is a curved surface while the second surface 40 is a planar surface. Unlike the thickness 42 which is homogeneous in the first embodiment, a thickness 94 between the contact surface 38 and the second convex surface 92 varies between the two walls 64, 66 in a plane perpendicular to the contact surface 38.

[0089] [Fig.6] schematically illustrates an electrical contact 140 according to a fourth embodiment. In the following, the elements bearing the same reference signs as those described previously will not be described again and reference is made to their description given in the preceding paragraphs.

[0090] The electrical contact 140 according to the fourth embodiment differs from the first embodiment in that a first locking surface 82 formed by a planar portion of the first circular base 52 of the transition portion 24 is larger than the first locking surface 60 according to the first embodiment. In the fourth embodiment, the inclination of the slope 56 of the transition surface 48 may be decreased compared to the first embodiment.

[0091] The first locking surface 82 in the fourth embodiment may be substantially identical to the first locking surface 82 in the second embodiment and the third embodiment, respectively.

[0092] The electrical contact 140 according to the fourth embodiment differs respectively from the first embodiment, the second embodiment and the third embodiment in that the transition portion 24, in particular the first portion 44 of the transition portion 24, is provided with a collar 142. The collar 142 is arranged on the outer circumferential wall 46 of the transition portion 24. The collar 142 defines a bearing surface 144. The bearing surface 144 is a flat surface. The bearing surface 144 may be parallel to the first circular base 52. Alternatively, the bearing surface 144 may be inclined relative to the plane of the first circular base 52. The bearing surface 144 of the collar 142 may serve to retain the electrical contact 140 in a connector housing, in particular in a direction going from the contact portion 20 towards the connection portion 22.The bearing surface 144 may be configured to abut against an element of the connector housing. The retention of the electrical contact 140 in a connector housing may thus be improved by means of the collar 142.

[0093] [Fig.7] schematically illustrates an electrical contact 150 according to a fifth embodiment. In the following, elements bearing the same reference signs as those described previously will not be described again and reference is made to their description made in the preceding paragraphs.

[0094] The electrical contact 150 differs respectively from the electrical contacts according to the previous embodiments in that the transition portion 24 comprises a recess 152. The feature of the recess 152 makes it possible to save material for the manufacture of the electrical contact. In particular, the volume of material of the transition portion 24 according to the fifth embodiment is smaller than the volume of material of the transition portion 24 according to the other embodiments described previously.

[0095] The recess 152 extends partially into the first portion 44. The recess 152 extends partially into the second portion 50. A bottom 154 of the recess 152 defines a flat surface parallel to the contact surface 38. The bottom 154 of the recess 152 can serve as a transition surface between the connection portion 22 and the transition portion 24. Thus, unlike the previous embodiments, the transition surface, i.e. the bottom 154 in the fifth embodiment, is parallel to the contact surface 38. In the previous embodiments, the transition surface 48 is inclined relative to the contact surface 38.

[0096] The bottom 154 of the recess 152 extends to a wall 156 of the second portion 44 of the transition portion 24. The wall 156 may be substantially parallel to the second circular base 54. Alternatively, the wall 156 may be inclined relative to the plane of the circular base 54.

[0097] Due to the presence of the recess 152, the transition portion 24 is provided with two side walls 158, 160 which extend respectively along the longitudinal direction 100. An outer face of each side wall 158, 160 corresponds respectively to a portion of the outer circumferential wall 46. The transition portion 24 has a substantially “U” shaped cross section, at least up to the wall 156. Beyond the wall 156, the first portion 44 of the transition portion 24 has a cylindrical cross section. The side walls 158, 160, in addition to the side walls 64, 66, contribute to the transmission of current in the transition portion 24. The feature of the recess 152 makes it possible to save material while ensuring satisfactory current transmission in the transition portion 24.

[0098] The thickness 42 of the connection portion 22 may be less than the thickness of the bottom 154 of the recess 152. This difference in thickness may form a shoulder between the contact surface 38 and the bottom 154 of the recess 152.

[0099] As illustrated by [Fig.7], a distance 170 between the side walls 64, 66 at the connection portion 22 is greater, in particular between 1.2 and 1.5 times greater, than a distance 172 between the side walls 158, 160. The distance 170 is defined parallel to the contact surface 38. The distance 172 is defined parallel to the bottom 154 of the recess 152. The characteristic of the recess 152 can make it possible to simplify the form factor of the electrical contact 150 by facilitating the transition between the U-shaped connection portion 22 and the cylindrical portion of the second portion 44.

[0100] [Fig.8] schematically illustrates a sectional view of a connector housing 200 comprising two electrical connectors 10. [Fig.8] illustrates only a partial view of the connector housing 200. In the following, the elements bearing the same reference signs as those described previously will not be described again and reference is made to their description given in the preceding paragraphs.

[0101] The connector housing 200 can be made of plastic, in particular by means of a plastic injection molding process. The connector housing 200 comprises a respective housing 202 for receiving each contact pin 26 of the electrical connectors 10. Each housing 202 comprises an opening 204 through which the contact pin 26 is introduced, in particular along the longitudinal direction 100. The opening 204 can have a circular shape. The dimension of the opening 204 is complementary to the diameter of the contact pin 26, in particular to the diameter of the contact pin 26 between the circumferential shoulder 34 and the end 28. The segment 36 of the contact pin 26 can have a diameter more larger than the opening 204. Thus, an insertion of the contact pin 26 in the longitudinal direction 100 can be blocked by a stop on the shoulder 34. Alternatively or in combination, the seal 12 arranged on the circumference of the segment 36 can make it possible to block the insertion of the contact pin 26 further towards the housing 202.

[0102] The seal 12 provides sealing between the housing 202 and the opening 204. The seal 12 is disposed between a tubular chimney 206 of the housing 200 and the segment 36 of the contact pin 26. The tubular chimney 206 extends from the opening 204 parallel to the longitudinal direction 100 and in a direction from the contact portion 20 to the connection portion 22. The tubular chimney 206 has a circumferential edge 208. The circumferential edge 208 may rest on the second circular base 54 of the transition portion 24 of the electrical contact 10. In particular, the circumferential edge 208 may rest on a chamfer or fillet defined between the second circular base 54 and the segment 36 of the contact pin 26. In the example of [Fig. 8], the segment 36 of contact pin 26 is covered by seal 12.

[0103] The housing 200 comprises an interface 210 through which the electrical connectors 10 are inserted. The interface 210 may be covered by a cover 212. The cover 212 comprises locking lances 214 which respectively abut on the first locking surface 60 and the second locking surface 62 of each electrical contact 10. The respective abutment of the locking lances 214 against the locking surfaces 62, 64 makes it possible to improve the retention of each electrical contact 10 in the connector housing 200.

[0104] The above description applies to each of the electrical connectors 10 and to each of the housings 202, which are identical. The number of housings 202 in the connector housing 200 is not limiting. The connector housing 200 can be adapted to receive the electrical contact 80 according to the second embodiment. The connector housing 200 can be adapted to receive the electrical contact 90 according to the third embodiment. The connector housing 200 can be adapted to receive the electrical contact according to the fourth embodiment. The connector housing 200 can be adapted to receive the electrical contact according to the fifth embodiment.

[0105] In each of the embodiments, the connection portion 22 may be configured such that only the contact surface 38 is weldable or bondable to an electrical conductor. Alternatively, the connection portion 22 may be configured such that the contact surface 38 and at least one of the side walls 64, 66 are weldable or bondable to an electrical conductor.

[0106] All the embodiments described above are not limiting but serve as examples illustrating the features and advantages of the invention. It is understood that all or part of the features described above may also be combined in different ways. It should be noted that an individual feature described in relation to one embodiment may be combined with another embodiment.

[0107] List of reference signs 1: electrical contact according to the state of the art 2: contact portion 3: connection portion 4: transition portion 5: flat contact surface 6: end 7: electrical conductor 10: electrical contact according to the first embodiment 12: Seal 20: contact portion 22: connection portion 24: transition portion 26: contact pin 28: hood 30, 32: end of the contact pin 34: shoulder 36: contact pin segment 38: flat contact surface 40: second surface of the connection portion 42: thickness of the connection portion 43: thickness of the first portion 44: first portion of the transition portion 46: external circumferential wall 48: transition surface 50: second portion of the transition portion 52: first circular base 54: second circular base 56: slope 58: rounded 60: first locking surface 62: second locking surface 64, 66: side walls 67: height of the side wall at the level of the first portion 68: height of the side wall at the connection portion 69: thickness of the side wall at the connection portion 70: free edge of the side wall 80: electrical contact according to the second embodiment 82: first locking surface 90: electrical contact according to the third embodiment 92: convex surface 94: thickness in the second embodiment 100: longitudinal direction 110, 120, 130: longitudinal central axis 140: electrical contact according to the fourth embodiment 142: collar 144: collar support surface 150: electrical contact according to the fifth embodiment 152: recess 154: bottom of the recess 156: wall 158, 160: side wall 170, 172: distance between side walls 200: connector housing 202: housing 204: opening 206: tubular chimney 208: circumferential edge 210: interface 212: cover 214: locking lance Al, A2, A3, A4: cross section

Claims

Claims

1. An electrical contact (10) comprising: a contact portion (20), a connection portion (22), the connection portion (22) comprising a planar contact surface (38) configured for electrical connection with an electrical conductor, and a transition portion (24), the transition portion (24) being disposed between the planar contact surface (38) and the contact portion (20) along a longitudinal direction (100) of the electrical contact (10), characterized in that at least one first side wall projects from the planar contact surface (38) and extends at least along the transition portion (24) relative to the longitudinal direction (100) of the electrical contact (10).

2. The electrical contact (10) according to claim 1, comprising a second side wall, and the two side walls are arranged opposite each other respectively along the longitudinal direction (100) of the electrical contact (10).

3. The electrical contact (10) according to claim 1 or 2, wherein the largest cross-section of the electrical contact (10) at the connection portion (22) is equal to or smaller than the smallest cross-section of the transition portion (24).

4. The electrical contact (10) according to one of the preceding claims, the planar contact surface (38) of which is configured to make an electrical connection with an electrical conductor by means of: laser welding, ultrasonic welding, electrical resistance welding, induction welding, or cold bonding with a conductive glue.

5. The electrical contact (10) according to one of the preceding claims, comprising a transition surface (48) and at least one first locking surface (60), the first locking surface (60) being substantially transverse to the planar contact surface (38), and the transition surface (48) connecting the first locking surface (60) to the flat contact surface (38).

6. The electrical contact (10) according to one of the preceding claims, the planar contact surface (38) of which is offset parallel to a longitudinal central axis (110) of the contact portion (20).

7. The electrical contact (10) according to one of the preceding claims, the height of the side wall (84, 86) of which from the planar contact surface (38) varies at least partially in an increasing manner in a direction going from the connection portion (22) towards the transition portion (24).

8. The electrical contact (10) according to one of the preceding claims, wherein the contact portion (20) is a solid contact pin (26).

9. The electrical contact (10) according to one of the preceding claims, characterized in that it is formed integrally in a single piece.

10. Connection assembly comprising an electrical contact (10) according to one of the preceding claims and an electrical conductor (7), in particular a conductive cable or a bus bar, wherein the electrical conductor (7) is soldered or glued to the planar contact surface (38), in particular only to the planar contact surface (38).

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