Electrical contact to make an electrical connection with an electrical conductor

Abstract

The present invention relates to an electrical contact (10) comprising: a contact portion (20), a connecting portion (22), and a transition portion (24). The connecting portion (22) comprises a contact surface (38), in particular a flat contact surface (38), configured for an electrical connection with an electrical conductor. The transition portion (24) is disposed between the contact surface (38) and the connecting portion (22) along a longitudinal direction (100) of the electrical contact (10). At least one first lateral 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 the 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 busbar. Ultrasonic welding, resistance welding, and induction welding are known methods for welding an electrical contact to a connector cable or busbar. Ultrasonic welding is a welding process that uses high-frequency vibrational energy. It is a solid-state welding process in that the materials being welded do not melt, unlike resistance welding. Resistance welding is performed under pressure and with a high electric current. With induction welding, heat is electromagnetically induced in the electrical contact.

[0003] In the automotive industry, for example, particularly for the charging port 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 in the prior art is illustrated by [Fig. 1]. The electrical contact 1 of [Fig. 1] comprises a contact portion 2, a connecting portion 3, and a transition portion 4 arranged between the contact portion 2 and the connecting portion 3 along a longitudinal direction 100 of the electrical contact 1. The connecting portion 3 comprises a flat contact surface 5. The end 6 of an electrical conductor 7 is welded by means of ultrasonic welding to the flat contact surface 5. The cross-sectional view (A), transverse to the longitudinal direction 100, shows that the cross-sectional area of ​​the electrical contact 1 at this point is equivalent to the sum of the cross-sectional area A1 of the end 6 of the electrical conductor 7 and the cross-sectional area A2 of the connecting 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 cross-sectional view (B) transverse to the longitudinal direction 100. In the example of [Fig.1], the cross-section is reduced by almost 50% between the cross-sectional view (A) and the cross-sectional view (B).

[0005] A cross-section that is too small at the transition portion is undesirable because it may 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 compared to 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 flat contact surface configured for an electrical connection with an electrical conductor, and a transition portion, the transition portion being disposed between the flat contact surface and the contact portion along a longitudinal direction of the electrical contact. At least one first lateral wall projects from the flat contact surface and extends at least along the transition portion relative to the longitudinal direction of the electrical contact.

[0008] The characteristic of the side wall allows for an increase in the cross-sectional area of ​​the transition portion. This increase in cross-sectional area reduces electrical resistance. Reducing resistance can prevent the electrical contact from heating up when an electric current passes through it. The transition portion is thus better suited for carrying high electric currents.

[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. Only the contact surface of the connecting 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-section at the transition portion is particularly advantageous because the electrical conductor would not contribute to the cross-section at that point since the transition portion is not configured to receive the electrical conductor.

[0011] Increasing the cross-sectional area at the transition portion allows for an advantageous reduction in the cross-sectional area at the connection portion, since the cross-sectional area of ​​the electrical conductor contributes to the total cross-sectional area at the connection portion. The potential reduction in the cross-sectional area of ​​the connection portion makes it possible, in particular, to reduce the thickness of the connection portion at the flat contact surface. A thinner flat contact surface is, for example, advantageous for facilitating certain welding processes and / or for saving material.

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

[0013] The side wall can be connected to the transition portion by a material bond. The side wall can project at an angle to the flat contact surface, in particular with an inclination between 45° and 135°, and more particularly with an inclination between 80° and 95°. The side wall can also project perpendicularly to the flat contact surface, i.e., with an inclination of 90°. Thus, the side wall can be parallel to a lateral side of a busbar, for example. This can facilitate welding or bonding between the parallel surfaces of the side wall and a lateral side of the busbar.

[0014] In particular, the electrical contact is configured for an electrical connection with a bus bar, including an insulating coating or not, by means of a welding process.

[0015] The connecting portion may include an opposing surface that is geometrically opposite to 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 can extend from the connection portion to the transition portion, in particular from a distal end of the connection portion to the transition portion. This can improve the mechanical strength of the electrical connector.

[0017] According to one embodiment, the electrical contact may include 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 lateral wall makes it possible to further increase the cross-section of the transition portion.

[0019] In addition, the two side walls can guide a conductor cable or a bus bar to be soldered inserted when the conductor cable or bus bar is inserted between the two side walls.

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

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

[0022] According to one embodiment, the largest cross-sectional area of ​​the electrical contact at the connection portion is equal to or less than the smallest cross-sectional area of ​​the transition portion. In particular, the largest cross-sectional area of ​​the electrical contact at the connection portion is strictly less than the smallest cross-sectional area of ​​the transition portion. This makes it possible to thin the electrical contact at the connection portion.

[0023] At least a portion of the transition portion may protrude from the contact portion and the connection portion. The protruding portion(s) may respectively form a support or a locking surface against which a connector housing, for example, may abut, particularly in the longitudinal direction. The protruding portion(s) may also serve to retain the connection device between a housing and a housing cover.

[0024] The transition portion may include a first portion. The first portion may have a solid, circular, disk-shaped cross-section. The first portion may have a constant cross-section. The first portion may provide a suitable surface for temperature measurement. The temperature measurement may be performed using a temperature sensor. It is sometimes necessary to monitor the temperature of an electrical contact, particularly 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 suitable surface for maintaining electrical contact during the ultrasonic welding process.

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

[0026] The electrical contact can 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 one first locking surface, the first locking surface being substantially transverse to the flat contact surface, and the surface transition connecting the first locking surface to the flat contact surface.

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

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

[0030] The locking surface can be formed by a protruding portion of the transition portion, in particular by a protruding portion of the first portion of the transition portion. The locking surface can be perpendicular to the flat contact surface.

[0031] According to one embodiment, the flat contact surface can be offset parallel to a longitudinal central axis of the contact portion. This allows the longitudinal central axis of an electrical conductor connected to the contact surface to be aligned with the longitudinal central axis of the contact portion. Aligning the longitudinal central axis of the electrical conductor with that of the contact portion results in a more compact electrical contact. This alignment can reduce the size of a cavity in a sealing element into which the electrical conductor can be housed.

[0032] According to one embodiment, the height of the side wall from the flat contact surface can vary, at least partially, in an increasing manner from the connection portion to the contact portion. Compared to a side wall with a constant height, this allows for a reduction in the side wall height and thus saves material for forming the electrical contact.

[0033] Alternatively, the height of the side wall from the flat contact surface can be constant in a direction from the connection zone to the contact zone. This makes it possible to obtain a homogeneous increase in mechanical strength along the longitudinal direction.

[0034] The contact portion can be configured to plug in with a conjugate electrical connector. The contact portion can be male or female. A male contact portion can be a pin. A female contact portion can include a hollow tubular housing to receive a connector. Conjugated male. In one embodiment, the contact portion may be a solid contact pin. The contact pin may be cylindrical. The contact pin may have one or more metallic coatings. The contact pin may have several metallic coatings of identical composition. Alternatively, the contact pin may have several metallic coatings of different compositions. For example, the contact pin may have a silver coating and a nickel underlayer. The contact pin may have an electroplated coating comprising silver, gold, or tin. The end of the contact portion may be fitted with a cap. The cap protects the end of the contact pin and reduces the risk of accidental contact. The cap thus provides finger protection, more commonly known as "touch-safe."The cap can be detachably arranged at the contact portion. The cap can be made from a dielectric material, for example, a plastic material.

[0035] Alternatively, the contact portion can be a contact socket. Unlike a solid contact pin, which has a solid structure, a contact socket has a hollow structure. The hollow structure of the contact socket is suitable for receiving an electrical conductor.

[0036] According to one embodiment, the electrical contact can be formed entirely in one piece. This eliminates assembly steps. The electrical connector can be formed from an electrically conductive material. The electrical connector can be formed from a metallic material. The electrical connector can be formed by a cold forming process. The electrical contact can be made of copper or a copper alloy, particularly a high-copper alloy. The use of copper is advantageous due to its very good electrical conductivity. The electrical contact can also 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 conductor cable or bus bar may only be welded or bonded to the flat contact surface. The connection assembly may be characterized by the absence of a weld between the side wall(s) and the conductor cable or bus bar. This embodiment is particularly suitable for ultrasonic welding between the conductor cable or bus bar and the electrical contact. The conductor cable or bus bar may be arranged in the connection portion. so that each side wall is spaced from the conductor cable or busbar. The greatest distance between the first and second side walls may be at least 5% and at most 30% greater than the transverse dimension of the conductor cable or busbar in a plane parallel to the flat contact surface. The greatest distance between the first and second side walls may exceed the diameter of the first portion of the transition section. The first portion may be a solid cylindrical section.

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

[0040] In the connection assembly, a longitudinal central axis of the conductor cable or bus bar can be aligned with a longitudinal central axis of the contact portion. This advantageously reduces the overall size of the connection assembly. This alignment can also reduce the size of a cavity in a sealing element into which the conductor cable or bus bar can be received.

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

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

[0043] A conductive cable may comprise a plurality of conductive metallic 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 flat 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 an 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 lateral 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 flat surface. A flat contact surface is suitable for making an electrical connection with a conductor cable, which can be flattened or pressed onto said flat contact surface. A flat contact surface is particularly suitable for making an electrical connection with a bus bar having at least one flat 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 conductor cable. A curved contact surface is particularly suitable for making an electrical connection with a cylindrical busbar, i.e., 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 busbar with a cylindrical cross-section and an electrical contact. The electrical contact may comprise: a contact portion, a connection portion, the connection portion comprising a curved contact surface and a transition portion, the transition portion being disposed between the curved contact surface and the contact portion along a longitudinal direction of the electrical contact. At least one first side wall may project 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 may be made between the electrical contact and the busbar at the curved contact surface.

[0051] The invention and its advantages will be explained in more detail below 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 prior art; [Fig.2] schematically illustrates an electrical contact according to a first embodiment; [Fig.3] schematically illustrates a set of connections 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 cross-sectional view of a connector housing comprising two electrical connectors according to the first embodiment.

[0053] Figure 2 schematically illustrates an electrical contact 10 according to a first embodiment. The electrical contact 10 is made from an electrically conductive material. The electrical contact 10 can be formed entirely from a single piece of metal. The electrical contact 10 comprises three portions along a longitudinal direction 100: a contact portion 20, a connecting portion 22, and a transition portion 24. The transition portion 24 is arranged between the contact portion 20 and the connecting portion 22 along a longitudinal direction 100.

[0054] The contact portion 20 is pluggable into a conjugate 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 referred to as a "contact pin." 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 include a circumferential shoulder 34. In particular, the contact pin 26 may include a single circumferential shoulder 34 along its length. The presence of the circumferential shoulder 34 forms a segment 36 between the first end 30 and the circumferential shoulder 34. A cross-section at segment 36 is larger than a cross-section of the rest of the contact pin 26. Segment 36 of the contact pin 26 is configured to receive a seal 12 (visible in [Fig. 3]), in particular an annular seal 12. The seal 12 may have an inner diameter approximately equal to the outer diameter of segment 36. The seal 12 may be held against segment 36 by friction.

[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 prior art (see [Fig. 1]). The presence of a single circumferential shoulder 34 on the contact portion 20 advantageously reduces the length of the contact portion 20 while still allowing satisfactory retention of the sealing gasket 12. It is understood that the length of the contact portion is defined from the longitudinal central axis 110.

[0058] The connection portion 22 is configured to make an electrical connection, in particular an electrical and mechanical connection, with an electrical conductor (visible in [Fig. 3]). The connection portion 22 includes 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 bonding. The contact surface 38 is flat. The flat contact surface 38 may be rectangular. The flat contact surface 38 may have a surface area between 5 square millimeters and 1000 square millimeters, in particular between 50 square millimeters and 250 square millimeters. The flat contact surface 38 serves as a support for welding or bonding with an electrical conductor. An electrical conductor, in particular a rigid busbar, may be placed, preferably flat, on the flat 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 weld the bus bar with the electrical contact 10 at the level of the flat contact surface 38.

[0060] Figure 3 illustrates a longitudinal cross-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 what follows, reference is made to Figures 2 and 3.

[0061] The connecting 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 connecting portion 22, is indicated by the datum symbol 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 external circumferential wall 46 extending 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, and 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 can 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 flows through it. The thickness of the first portion 44 can be adapted to allow easier handling of the electrical contact 100 during the welding or bonding process, or during the assembly of the electrical contact 100 in a connector housing, or both.

[0064] The second portion 50 (see [Fig.3]) connects the connecting 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 flat contact surface 38. In the illustrated example, the second portion has a solid structure, as illustrated by the cross-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° with respect to the flat contact surface 38. The slope 56 may have a rounded edge 58, in particular towards the crest of the slope 56 (visible in [Fig. 3]). The slope 56 is downward in a direction from the transition portion 24 towards the flat contact surface 38. The transition surface 48 is inclined with respect to the first circular base 52.

[0066] The second portion 44 projects beyond the first portion 50. The projecting surface(s) of the second portion 44 can serve as a locking surface, forming a stop surface for a connector housing, for example. A locking pin of a connector housing can abut against the locking surface, which is further described in the following paragraph. Unintentional rotation, unintentional translational movement, or both, of the electrical contact 100 can be prevented. The first circular base 52 of the first portion 44 can include a first locking surface 60. The first locking surface 60 is a flat surface. The first locking surface 60 is oriented towards the flat contact surface 38. The transition surface 48 connects the first locking surface 60 to the flat contact surface 38.

[0067] The first circular base 52 of the first portion 44 may include 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 towards 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 flat contact surface 38 is arranged parallel to and offset from the longitudinal central axis 110 of the contact portion 20 and the longitudinal central axis 120 of the transition portion 24. Thus, the flat contact surface 38 is positioned eccentrically with respect to the first circular base 52 of the first portion 44. This offset of the flat 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 reduces the overall size of the electrical contact 10.

[0070] Unlike the electrical contact 1 according to the prior art (see [Fig. 1]), 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 what follows, the description of the side wall 64 also applies to the side wall 66.

[0071] The side wall 64 projects from the flat contact surface 38. In particular, the side wall 64 projects perpendicularly to the flat 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 lateral walls 64, 66. The lateral wall 64 has a free edge 70. The free edge 70 can 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 flat contact surface 38 and a free edge 70. In this example, the height 68 is defined along a direction perpendicular to the flat contact surface 38. The height 68 of the side wall 64 can be between 1 millimeter and 50 millimeters. The height 68 of the side wall 64 can 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 along a direction parallel to the flat contact surface 38, as shown in [Fig. 2] and view (A) of [Fig. 3]. The thickness 69 can be substantially the same as the thickness 42. Preferably, the thickness 69 can be greater than the thickness 42.

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

[0074] The first portion 50 has a thickness 43, as shown in view (B) of [Fig. 3]. The thickness 43 of the second portion 50 can be substantially the same as the thickness 42 of the connecting portion 22. Preferably, the thickness 43 of the second portion 50 can be greater than the thickness 42 of the connecting portion 22. This makes it possible to provide an electrical contact having a connecting portion 22 that is thinner than the second portion 50.

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

[0076] The cross-sectional view (A) of [Fig. 3], transverse to the longitudinal direction 100, shows that the cross-sectional area of ​​the electrical contact 10 at this location is equivalent to the sum of the cross-sectional area A1 of the end 6 of the electrical conductor 7 and the cross-sectional area A3 of the connecting portion 22. The cross-sectional area A3 of the connecting portion 22 includes the cross-sectional thickness 42 as well as the cross-sectional area of ​​each of the side walls 64, 66. The cross-sectional area A3 of the electrical contact 10 is larger than the cross-sectional area A2 of the electrical contact 1 according to the prior art illustrated in [Fig. 1] and which does not include side walls. The increased cross-section reduces the electrical resistance. This reduction in resistance can prevent the electrical contact from heating up when an electric current passes through it.

[0077] Advantageously, the side walls 64, 66 allow, in particular, for an increase in the cross-sectional area of ​​the electrical contact 10 in the transition portion 24, especially at the level of the second portion 50 of the transition portion 24. The cross-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 point (see cross-sectional view (B) of the Figure), the cross-sectional area of ​​the electrical contact 10 is defined solely by the cross-sectional area 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 prior art illustrated by [Fig.1] and which does not include side walls.

[0079] The cross-section A4 of the transition portion 24 can be substantially equal to the cross-section A3 of the connecting 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 connecting portion 22.

[0080] In particular, the sum of the cross-sections Al and A3 is at most two greater, in particular at most 1.5 greater, 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 (Al + A3) at the connection portion 22, to which the cross-section Al of the electrical conductor 6 contributes.

[0081] Better continuity of electric current transmission can be achieved, in particular at the level of 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] Figure 4 schematically illustrates an electrical contact 80 according to a second embodiment. In what follows, elements bearing the same reference numerals as those described previously will not be described again, and reference is made to their description 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 flat 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 can be reduced compared to the first embodiment.

[0084] In the first embodiment, the height 68 of the side walls 64, 66 is constant along the flat 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 flat contact surface 38 varies at least partially in an increasing direction from the connecting portion 22 to the transition portion 24. In the second embodiment, a ramp 88 connects the flat 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 required to manufacture the walls 64, 66 according to the first embodiment.

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

[0086] The electrical contact 80 according to the second embodiment makes it possible to reduce the amount of material needed 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] Figure 5 schematically illustrates an electrical contact 90 according to a third embodiment. In what follows, elements bearing the same reference numerals as those described previously will not be described again, and reference is made to their description in the preceding paragraphs.

[0088] The electrical contact 90 according to the third embodiment differs respectively from the first and second embodiments in that, in the connection portion 22, the second surface 92 opposite the flat 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 flat surface. Unlike the thickness 42, which is uniform 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] Figure 6 schematically illustrates an electrical contact 140 according to a fourth embodiment. In what follows, the elements bearing the same symbols reference is made to those described previously, which will not be described again, and reference is made to their description 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 flat 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 reduced compared to the first embodiment.

[0091] The first locking surface 82 in the fourth embodiment can 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 external 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 can be parallel to the first circular base 52. Alternatively, the bearing surface 144 can be inclined with respect to the plane of the first circular base 52. The bearing surface 144 of the collar 142 can serve to retain the electrical contact 140 in a connector housing, in particular in a direction from the contact portion 20 to the connection portion 22.The bearing surface 144 can be configured to abut against an element of the connector housing. The retention of the electrical contact 140 in a connector housing can thus be improved by means of the collar 142.

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

[0094] The electrical contact 150 differs from the electrical contacts in the preceding embodiments in that the transition portion 24 includes a recess 152. The feature of the recess 152 allows for material savings in the manufacture of the electrical contact. In particular, the volume of material in the transition portion 24 according to the fifth embodiment is smaller than the volume of material in 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 connecting 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 with respect 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 with respect 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 lateral walls 158, 160 extending respectively along the longitudinal direction 100. An outer face of each lateral 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 lateral walls 158, 160, in addition to the lateral walls 64, 66, contribute to the transmission of current in the transition portion 24. The characteristic 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 connecting 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 in [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 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] Figure 8 schematically illustrates a cross-sectional view of a connector housing 200 comprising two electrical connectors 10. Figure 8 illustrates only a partial view of the connector housing 200. In what follows, elements bearing the same reference numerals as those described previously will not be described again and reference is made to their description in the preceding paragraphs.

[0101] The connector housing 200 can be made of plastic, in particular by a plastic injection molding process. The connector housing 200 includes a respective recess 202 for receiving each contact pin 26 of the electrical connectors 10. Each recess 202 includes an opening 204 through which the contact pin 26 is inserted, in particular in the longitudinal direction 100. The opening 204 may be circular. 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 may have a larger diameter than the opening 204. Thus, insertion of the contact pin 26 in the longitudinal direction 100 can be prevented by a stop on the shoulder 34.Alternatively or in combination, the sealing gasket 12 arranged on the circumference of segment 36 can allow the insertion of the contact pin 26 to be blocked further towards the housing 202.

[0102] The sealing gasket 12 provides a seal between the housing 202 and the opening 204. The sealing gasket 12 is located 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 can rest on the second circular base 54 of the transition portion 24 of the electrical contact 10. In particular, the circumferential edge 208 can 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 the Contact pin 26 is covered by sealing gasket 12.

[0103] The housing 200 includes an interface 210 through which the electrical connectors 10 are inserted. The interface 210 can be covered by a cover 212. The cover 212 includes locking lances 214 which respectively abut against 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 improves 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 limited. 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 embodiment, the connection portion 22 can be configured such that only the contact surface 38 is weldable or bondable to an electrical conductor. Alternatively, the connection portion 22 can 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 exhaustive 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 section 5: flat contact surface 6: endpoint 7: electrical conductor 10: electrical contact according to the first embodiment 12: sealing gasket 20: contact portion 22: connection portion 24: transition section 26: Contact pin 28: cap 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 connecting portion 43: thickness of the first portion 44: first part of the transition section 46: outer circumferential wall 48: transition surface 50: second part of the transition section 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 point 69: thickness of the side wall at the connection point 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: bearing surface of the collar 150: electrical contact according to the fifth embodiment 152: obviously 154: bottom of the hollow 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: lid 214: Locking lance Al, A2, A3, A4: cross section

Claims

Demands

1. An electrical contact (10) comprising: a contact portion (20), a connecting portion (22), and a transition portion (24), the transition portion (24) being arranged between the contact portion (20) and the connecting portion (22) along a longitudinal direction (100) of the electrical contact (10), and the contact portion (20) being a solid contact pin (26), and the connecting portion (22) comprising a flat contact surface (38) configured for an electrical connection with an electrical conductor, and the transition portion (24) being disposed between the flat contact surface (38) and the contact portion (20) along a longitudinal direction (100) of the electrical contact (10), and at least one first side wall protruding from the flat contact surface (38) and extending 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, of which a cross-section of the connection portion (22), respectively of the transition portion (24), corresponds to a surface of the connection portion (22), respectively of the transition portion (24), in a plane perpendicular to the longitudinal direction (100) of the electrical contact (10), and the largest cross-section of the electrical contact (10) at the connection portion (22) is equal to or less than the smallest cross-section of the transition portion (24).

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

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

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

8. The electrical contact (10) according to any one of the preceding claims, characterized in that it is formed entirely in one piece.

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

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