Electrical contact for forming electrical connection with electrical conductor

Abstract

To provide an electrical contact having a high current carrying capacity, particularly for charging an electric vehicle.SOLUTION: An electrical contact (10) includes a contact portion (20), a connection portion (22) and a transition portion (24). The connection portion (22) includes a contact surface (38), in particular a flat contact surface (38), configured for electrical connection with an electrical conductor. The transition portion (24) is disposed 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).SELECTED DRAWING: Figure 2

Description

Technical Field

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

Background Art

[0002] In most applications, it is desirable to provide a stable and highly durable electrical connection between an electrical contact and a connector cable or a bus bar. Ultrasonic welding, electric resistance welding or induction welding are known methods for welding an electrical contact to a connector cable or a bus bar. Ultrasonic welding is a welding process using high-frequency vibration energy. This is a solid-phase welding process characterized in that, unlike electric resistance welding, the material to be welded does not melt. Electric resistance welding is performed using a strong current under pressure. In induction welding, heat is electromagnetically induced in the electrical contact.

[0003] For example, in the automotive industry, it is desirable to provide an electrical contact having a high current transmission capacity, especially for charging electric vehicles. A low current transmission capacity can cause undesirable overheating of the electrical contact.

[0004] An electrical contact known in the prior art is shown in FIG. 1. The electrical contact 1 in FIG. 1 includes a contact portion 2, a connection portion 3, and a transition portion 4 disposed between the contact portion 2 and the connection portion 3 along the longitudinal direction 100 of the electrical contact 1. The connection portion 3 includes a flat contact surface 5. The end portion 6 of the conductor 7 is welded to the flat contact surface 5 by ultrasonic welding. The cross-sectional view (A) taken across the longitudinal direction 100 shows that the cross-section of the electrical contact 1 at this location corresponds to the sum of the cross-section A1 of the end portion 6 of the conductor 7 and the cross-section A2 of the connection portion 3. At the boundary between the connection portion 3 and the transition portion 4, as shown in the cross-sectional view (B) taken across the longitudinal direction 100, the cross-section of the electrical contact 1 is simply equal to the cross-section A2 of the connection portion 3. In the example of FIG. 1, the cross-section is reduced by approximately 50% between the cross-sectional view (A) and the cross-sectional view (B).

[0005] If the cross-section in the transition portion is too small, it may not be possible to sufficiently transmit current, especially high-voltage direct current, which is undesirable.

Summary of the Invention

Problems to be Solved by the Invention

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

Means for Solving the Problems

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

[0008] Due to the characteristics of the side wall, it is possible to increase the cross-section of the transition part. By increasing the cross-section, it is possible to reduce the electrical resistance. By reducing the resistance, it is possible to avoid overheating of the electrical contact during the passage of current. Therefore, the transition part is more suitable for the passage of strong current.

[0009] The transition part is defined as the part adjacent to the contact surface. In particular, the contact surface and the transition part do not even partially overlap each other. Only the contact surface of the connection part can be configured to be in surface contact with the conductor. In particular, the transition part is not adapted to receive the conductor. The transition part may be configured so as not to be in surface contact with the conductor when the conductor is electrically connected to the electrical contact.

[0010] Since the transition part is not configured to receive the conductor, increasing the cross-section in the transition part is particularly advantageous because the conductor does not contribute to the cross-section at this location.

[0011] In the connection part, since the cross-section of the conductor contributes to the overall cross-section, by increasing the cross-section in the transition part, it is possible to advantageously reduce the cross-section in the connection part. Since it is possible to reduce the cross-section of the connection part, in particular, it is possible to reduce the thickness of the connection part on the flat contact surface. The thinner flat contact surface is advantageous, for example, to facilitate a specific welding process and / or to enable material savings.

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

[0013] The side wall may be integrally connected to the transition part. The side wall may protrude so as to be inclined with respect to the flat contact surface, particularly at an inclination between 45° and 135°, and more particularly at an inclination between 80° and 95°. The side wall may protrude perpendicular to the flat contact surface, i.e., at an inclination of 90°. Thus, the side wall may be parallel to the side surface of the bus bar, for example. This can facilitate welding or bonding between the side wall and the parallel surface of the side of the bus bar.

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

[0015] The connection part may comprise an opposite surface that is geometrically opposite to the flat contact surface. The opposite surface may be flat. The opposite surface may be parallel to the flat contact surface. Alternatively, the opposite surface may be a curved surface.

[0016] According to one embodiment, the side wall may extend from the connection part to the transition part, in particular from the distal end of the connection part to the transition part. 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 to each other along the longitudinal direction of the electrical contact.

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

[0019] In addition, the two side walls may make it possible to guide the inserted conductor cable or bus bar when the conductor cable or bus bar to be welded is inserted between the two side walls.

[0020] The two side walls may be symmetric 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 connection part, the transition part, or both of them may have a "U" shape. The "U" shape refers to the shape of the letter "U" in the Latin alphabet, and the central part of the "U" shape is flat to correspond to the flat contact surface. This specific geometry makes it possible to improve the mechanical strength of the electrical contact, which is particularly advantageous for withstanding well, for example, vibrations induced by ultrasonic welding. Ultrasonic welding may actually 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 in the connection part is equal to or smaller than the smallest cross-section of the transition part. In particular, the largest cross-section of the electrical contact in the connection part is strictly smaller than the smallest cross-section of the transition part. Thus, the electrical contact can be made thinner at the connection part.

[0023] At least one part of the transition part may protrude from the contact part and the connection part. Each of the at least one protrusion may form a support or locking surface, for example, where the connector housing can abut particularly in the longitudinal direction. The at least one protrusion may make it possible to hold the connection device between the housing and the housing cover.

[0024] The transition part may comprise a first part. The first part may have a solid disk-shaped cross-section. The first part may have a constant cross-section. The first part may provide a surface adapted for temperature measurement. The temperature measurement may be performed by a temperature sensor. In fact, it may be necessary to monitor the temperature of the electrical contact, especially when dealing with electrical contacts used for charging an electric vehicle in a charging base. Alternatively or in combination, the first part may provide a surface adapted to hold the electrical contact during an ultrasonic welding process.

[0025] According to one embodiment, the flat contact surface may be configured to form an electrical connection with the conductor by laser welding, ultrasonic welding, resistance welding, induction welding, or cold bonding with a conductive adhesive. Since the contact surface is flat, it is particularly suitable for welding and bonding. In particular, the flat contact surface is particularly desirable for ultrasonic welding.

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

[0027] According to one embodiment, the electrical contact may include a transition surface and at least one first locking surface, the first locking surface being positioned to intersect substantially with the flat contact surface, and the transition surface connecting the first locking surface to the flat contact surface.

[0028] The transition surface is bounded by at least one side wall, particularly two side walls. The transition surface may be a flat surface. The transition surface may be formed by a descending slope from the transition part to the flat 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 makes it possible to save materials.

[0029] The transition part may include a second part, and the second part may be arranged between the first part of the transition part and the connection part. The second part of the transition part may include a transition surface.

[0030] The locking surface may be formed by a protrusion of the transition part, particularly a protrusion of the first part of the transition part. The locking surface may be perpendicular to the flat contact surface.

[0031] According to one embodiment, the flat contact surface may be offset parallel to the longitudinal central axis of the contact portion. This makes it possible to align the longitudinal central axis of the conductor connected to the contact surface with the longitudinal central axis of the contact portion. By aligning the longitudinal central axis of the conductor with the longitudinal central axis of the contact portion, it becomes possible to obtain a smaller electrical contact. This alignment makes it possible to reduce the size of the cavity of the sealing element into which the conductor can be received.

[0032] According to one embodiment, the height of the side wall from the flat contact surface may change so as to increase at least partially in the direction from the connection portion to the contact portion. This makes it possible to reduce the height of the side wall compared to a side wall having a constant height, and thus save the material for forming the electrical contact.

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

[0034] The contact portion may be configured to be inserted into a mating electrical connector. The contact portion may be male or female. The male contact portion may be a pin. The female contact portion may include a hollow tubular receiving portion for receiving a mating male connector. According to 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 a plurality of metal coatings of the same composition. Alternatively, the contact pin may have a plurality of metal coatings with different compositions from each other. As an example, the contact pin may have a silver coating and a nickel underlayer. The contact pin may have a galvanic coating containing silver, gold or tin. A cap may be provided at the end of the contact portion. The cap can protect the end of the contact pin and reduce the risk of contact. Thus, the cap provides protection for fingers, more commonly known as "touch-safe". The cap may be removably arranged on the contact portion. The cap may be made of a dielectric material, such as a plastic material.

[0035] Alternatively, the contact portion may be a contact socket. Different from the solid contact pin having a solid structure, the contact socket has a hollow structure. The hollow structure of the contact socket is adapted to receive a conductor.

[0036] According to one embodiment, the electrical contact may be integrally formed as a single part. This eliminates the assembly process. The electrical connector may be formed from a conductive material. The electrical connector may be formed from a metal material. The electrical connector may be formed by a cold forming process. The electrical contact may be made of copper or a copper alloy, particularly a copper alloy having 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 realized by a connection assembly comprising an electrical contact according to at least one of the above-described embodiments and a conductor, particularly a conductor cable or a bus bar, and the conductor is welded or adhered to a flat contact surface.

[0038] In particular, the conductor cable or busbar may be welded or adhered only to the flat contact surface. The connection assembly may be characterized by the absence of welding between at least one side wall and the conductor cable or busbar. This embodiment is particularly suitable for ultrasonic welding between the conductor cable or busbar and the electrical contact. The conductor cable or busbar may be arranged at the connection portion such that each side wall is spaced apart from the conductor cable or busbar. The maximum distance between the first side wall and the second side wall may be at least 5% and at most 30% greater than the lateral dimension of the conductor cable or busbar in a plane parallel to the flat contact surface. The maximum distance between the first side wall and the second side wall may be greater than the diameter of the first portion of the transition portion. The first portion may be a cylindrical solid portion.

[0039] Alternatively, the conductor cable or busbar may be welded or adhered to the flat contact surface and at least one side wall, particularly both side walls. This advantageously makes it possible to increase the contact surface between the conductor cable or busbar and the electrical contact. This embodiment is particularly suitable for electric resistance welding between the conductor cable or busbar and the electrical contact.

[0040] In the connection assembly, the longitudinal central axis of the conductor cable or busbar may be aligned with the longitudinal central axis of the contact portion. This advantageously makes it possible to reduce the bulk of the connection assembly. This alignment can be used to reduce the size of the cavity of the sealing element into which the conductor cable or busbar can be received.

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

[0042] According to one embodiment, the connection assembly may comprise an electrical contact and a busbar, in particular a busbar having at least one flat surface, more particularly a busbar with a rectangular cross-section.

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

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

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

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

[0047] According to another aspect of the invention, the object of the invention can be achieved by an electrical contact comprising a contact portion, a connection portion having a contact surface configured for electrical connection with a conductor, and a transition portion disposed between the contact surface and the contact portion along the 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 with respect to the longitudinal direction of the electrical contact.

[0048] According to one embodiment of this aspect, the contact surface may be a flat surface. The flat contact surface is adapted to form an electrical connection with a conductor cable that can be pressed against or onto the flat contact surface. The flat contact surface is particularly suitable for forming an electrical connection with a busbar having at least one flat surface.

[0049] Alternatively, according to another embodiment of this aspect, the contact surface may be a curved surface. The curved contact surface is suitable for forming an electrical connection with the conductor cable. The curved contact surface is particularly suitable for forming an electrical connection with a cylindrical bus bar, i.e., a bus bar 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 a connection assembly comprising a bus bar with a cylindrical cross-section and an electrical contact. The electrical contact includes a contact portion, a connection portion, where the connection portion comprises a curved contact surface, and a transition portion, where the transition portion is arranged between the curved contact surface and the contact portion along the longitudinal direction of the electrical contact. At least one first side wall may protrude from the curved contact surface and extend at least along the transition portion with respect to the longitudinal direction of the electrical contact. The electrical connection may be formed between the electrical contact and the bus bar at the curved contact surface.

[0051] Hereinafter, the present invention and its advantages will be described in more detail using exemplary embodiments and based on the following attached drawings.

Brief Description of the Drawings

[0052]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

[0053] FIG. 2 schematically shows an electrical contact 10 according to the first embodiment. The electrical contact 10 is made of a conductive material. The electrical contact 10 may be integrally formed as a single metal component. The electrical contact 10 includes three portions along the longitudinal direction 100, namely, a contact portion 20, a connection portion 22, and a transition portion 24. The transition portion 24 is disposed between the contact portion 20 and the connection portion 22 along the longitudinal direction 100.

[0054] The contact portion 20 can be inserted into a mating electrical contact (not shown), particularly in the longitudinal direction 100. In the illustrated example, the contact portion 20 is a contact pin 26, more generally known as a "pin contact". 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. As shown in the example of FIG. 2, a cap 28 may be provided at the second end 32.

[0056] The contact pin 26 may comprise a circumferential shoulder 34. In particular, the contact pin 26 may comprise a single circumferential shoulder 34 over its length. The presence of the circumferential shoulder 34 forms a segment 36 between the first end 30 and the circumferential shoulder 34. The cross-section in the segment 36 is larger than the cross-section in other parts of the contact pin 26. The segment 36 of the contact pin 26 is configured to receive the seal 12 (shown in FIG. 3), in particular the annular seal 12. The seal 12 may have an inner diameter substantially equal to the outer diameter of the segment 36. The seal 12 may be held by friction on the segment 36.

[0057] The contact portion 20 may be characterized by the absence of a collar. A collar may be formed between two consecutive circumferential shoulders. For example, three consecutive collars are visible in 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 in the contact portion 20 advantageously makes it possible to reduce the length of the contact portion 20 while enabling sufficient retention of the seal 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 form an electrical connection, in particular an electrical and mechanical connection, with a conductor (shown in FIG. 3). The connection portion 22 has a contact surface 38. The contact surface 38 is configured for an electrical connection with a conductor (shown in FIG. 3) by welding or adhesion. The contact surface 38 is flat. The flat contact surface 38 may have a rectangular shape. 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 functions as a support for welding or adhesion with the conductor. A conductor, in particular a rigid bus bar, may be preferably arranged flat on the flat contact surface 38.

[0059] When an electrical connection is formed using an ultrasonic welding process, the active part of the sonotrode may be moved above the bus bar and vibrated to weld the bus bar to the electrical contact 10 at the flat contact surface 38.

[0060] FIG. 3 shows a longitudinal cross-section of the electrical contact 10 and two cross-sections of the electrical contact 10. FIG. 3 also shows a conductor 7 with an end portion 6 disposed on the flat contact surface 38 of the electrical contact 10. The electrical contact 10 and the conductor 7 form a connection assembly. Hereinafter, reference is made to FIGS. 2 and 3.

[0061] The connecting portion 22 includes a second surface 40 on the side opposite to the flat contact surface 38. In the example of FIG. 2, the second surface 40 is a flat surface. The flat contact surface 38 and the second surface 40 are parallel to each other and in the longitudinal direction 100. The distance between the flat contact surface 38 and the second surface 40, in other words, the thickness of the connecting portion 22, is indicated by reference numeral 42 in FIGS. 2 and 3.

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

[0063] The first portion 44 has a cylindrical shape defined by an outer peripheral 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 or 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 enable temperature measurement at the peripheral wall 46 of the transition portion 24, particularly for monitoring the temperature of the electrical contact 100 when current flows through the electrical contact 100. The thickness of the first portion 44 may be adapted to facilitate the manipulation of the electrical contact 100 during a welding or bonding process, or when assembling the electrical contact 100 into the connector housing, or both.

[0064] A 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 flat contact surface 38. In the illustrated example, as shown in the cross-sectional view of FIG. 3, the second portion has a solid structure.

[0065] The second portion 50 comprises a transition surface 48. In a first embodiment, the transition surface 48 defines an inclined surface 56, particularly an inclined surface of 30° to 45° with respect to the flat contact surface 38. The inclined surface 56 may particularly have a rounding 58 towards the top of the inclined surface 56 (shown in FIG. 3). The inclined surface 56 descends 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 with respect to the first portion 50. At least one projecting surface of the second portion 44 can each function as a locking surface, for example by forming an abutment surface against the connector housing. The locking lance of the connector housing may abut against the locking surface, which will be further described in the following paragraphs. Unintended rotation, unintended translational movement, or both of the electrical contact 100 can be avoided. The first circular base 52 of the first portion 44 may comprise a first locking surface 60. The first locking surface 60 is a flat surface. The first locking surface 60 is directed 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 (shown in FIG. 3). The second locking surface 62 is a flat surface. The second locking surface 62 faces 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 may not have a 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 arranged eccentrically with respect to the first circular base 52 of the first portion 44. This offset of the flat contact surface 38 enables the longitudinal central axis 130 of the 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 (shown in FIG. 3). This arrangement makes it possible to reduce the bulk of the electrical contact 10.

[0070] Unlike the electrical contact 1 (see FIG. 1) according to the prior art, the electrical contact 10 further includes two side walls 64, 66. In the first embodiment, the side walls 64, 66 are symmetric with respect to each other. Thus, the following 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 perpendicular 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, particularly to the first circular base 52 of the first portion 44. The two side walls 64, 66 extend on both sides of the second portion 50 of the transition portion 24. Thus, the transition surface 48 is at least partially bounded by the side walls 64, 66 respectively. The side wall 64 has a free edge 70. The free edge 70 may be rounded.

[0072] In the connection part 22, as shown in FIG. 3(A), the side wall 64 has a height 68 defined between the flat contact surface 38 and the free edge 70. In this example, the height 68 is defined along the direction perpendicular to the flat 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 part 22. In addition, as shown in FIGS. 2 and 3(A), in the connection part 22, the side wall 64 has a thickness 69 defined in the direction parallel to the flat contact surface 38. The thickness 69 may be substantially the same as the thickness 42. Preferably, the thickness 69 may be greater than the thickness 42.

[0073] In the first part 50, as shown in FIG. 3(B), the side wall 64 has a height 67. The height 67 may be substantially equal to the height 68.

[0074] As shown in FIG. 3(B), the first part 50 has a thickness 43. The thickness 43 of the second part 50 may be substantially the same as the thickness 42 of the connection part 22. Preferably, the thickness 43 of the second part 50 may be greater than the thickness 42 of the connection part 22. This makes it possible to provide an electrical contact having a connection part 22 thinner than the second part 50.

[0075] The two side walls 64, 66 are arranged on opposite sides of each other along one side of the flat contact surface 38 in the longitudinal direction 100 of the electrical contact 10. In the connection part 22, the presence of the two side walls 64, 66 results in a cross-section in the form of a "U". The "U" shape refers to the shape of the letter "U" in the Latin alphabet, and the central part of the "U" shape is flat because it corresponds to the flat contact surface 38.

[0076] Cross-sectional view (A) of FIG. 3 across the longitudinal direction 100 shows that the cross-section of the electrical contact 10 at this location corresponds to the sum of the cross-section A1 of the end portion 6 of the conductor 7 and the cross-section A3 of the connecting portion 22. The cross-section A3 of the connecting portion 22 includes the cross-sections of the thickness cross-section 42 and 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 shown in FIG. 1 and without side walls. By increasing the cross-section, it becomes possible to reduce the electrical resistance. By reducing the resistance, it becomes possible to avoid overheating of the electrical contact during the passage of current.

[0077] The side walls 64, 66 are particularly advantageous in that they make it possible to increase the cross-section of the electrical contact 10, particularly in the transition portion 24, and particularly in the second portion 50 of the transition portion 24. Cross-sectional view (B) of FIG. 3 shows the second portion 50 which is the portion where the end portion 6 of the conductor 7 does not extend beyond. At this location (see cross-sectional view (B) of FIG. 3), 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 prior art shown in FIG. 1 and without side walls.

[0079] The cross-section A4 of the transition portion 24 may be substantially equal to the cross-section A3 of the connecting portion 22. Preferably, the cross-section A4 of the transition portion 24 is larger than the cross-section A3 of the connecting portion 22, particularly strictly larger.

[0080] In particular, the sum of the cross-sections A1 and A3 is at most twice as large as the cross-section A4, particularly at most 1.5 times as large. This prevents the cross-section A4 of the electrical connector 10 in the transition portion 24 from becoming too small compared to the cross-section (A1 + A3) in the connecting portion 22 where the cross-section A1 of the conductor 6 contributes.

[0081] In particular, in the second portion 50 of the transition portion 24, that is, the portion where the end portion 6 of the conductor 7 does not extend beyond and thus the conductor 7 does not contribute to the cross-section capable of conducting current at that position, better continuity of current transmission can be achieved.

[0082] Figure 4 schematically shows the electrical contact 80 according to the second embodiment. Hereinafter, elements having the same reference numerals as those described above will not be described again, and the description made in the previous paragraphs is referred to.

[0083] The electrical contact 80 according to the second embodiment is different from the first embodiment in that the first locking surface 82 formed by the flat portion of the first circular base 52 of the transition portion 24 is larger than the first locking surface 60 in the first embodiment. In the second embodiment, the inclination of the inclined surface 56 of the transition surface 48 may be reduced as compared with 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 is different from the first embodiment in that the height of each of the side walls 84, 86 from the flat contact surface 38 changes so as to increase at least partially in the direction from the connecting portion 22 to the transition portion 24. In the second embodiment, the lamp 88 is connected to each corresponding free edge 70 of the flat contact surface 38. Therefore, the volume of the material required for manufacturing the walls 84, 86 in the second embodiment is smaller than the volume of the material required for manufacturing the walls 64, 66 in the first embodiment.

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

[0086] The electrical contact 80 according to the second embodiment enables the amount of material required for manufacturing the electrical contact to be reduced while ensuring sufficient transmission continuity because the cross section A4 of the transition portion 24, that is, the cross section in the second portion 50 of the transition portion 24, is at least substantially the same as that of the first embodiment in the cross section shown in FIG. 3(B).

[0087] FIG. 5 schematically shows an electrical contact 90 according to a third embodiment. Hereinafter, elements having the same reference numerals as those described above will not be described again, and the descriptions made in the previous paragraphs are referred to.

[0088] The electrical contact 90 according to the third embodiment is different from the first and second embodiments in that, at the connecting portion 22, the second surface 92 on the opposite side of the flat contact surface 38 is a second convex surface 92. In other words, the second surface 92 is a curved surface, and the second surface 40 is a flat surface. Different from the uniform thickness 42 in the first embodiment, the 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 shows an electrical contact 140 according to a fourth embodiment. Hereinafter, elements having the same reference numerals as those described above will not be described again, and the descriptions made in the previous paragraphs are referred to.

[0090] The electrical contact 140 according to the fourth embodiment is different from the first embodiment in that the first locking surface 82 formed by the 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 with respect to the first embodiment.

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

[0092] The electrical contact 140 according to the fourth embodiment differs from the first, second, and third embodiments in that a flange 142 is provided on the transition portion 24, particularly on the first portion 44 of the transition portion 24. The flange 142 is disposed on the outer peripheral wall 46 of the transition portion 24. The flange 142 defines a support surface 144. The support surface 144 is a flat surface. The support surface 144 may be parallel to the first circular base 52. Alternatively, the support surface 144 may be inclined with respect to the plane of the first circular base 52. The support surface 144 of the flange 142 may be used to hold the electrical contact 140 in the connector housing, particularly in the direction from the contact portion 20 to the connection portion 22. The support surface 144 may be configured to abut against an element of the connector housing. Thus, the flange 142 can improve the holding property of the electrical contact 140 to the connector housing.

[0093] FIG. 7 schematically shows an electrical contact 150 according to a fifth embodiment. Hereinafter, elements having the same reference numerals as those described above will not be described again, and the descriptions made in the previous paragraphs are referred to.

[0094] The electrical contact 150 differs from the electrical contacts according to the previous embodiments in that the transition portion 24 includes a recess 152. The features of the recess 152 make it possible to reduce the material for manufacturing the electrical contact. In particular, the volume of the material of the transition portion 24 according to the fifth embodiment is smaller than the volume of the material of the transition portion 24 according to the other embodiments described above.

[0095] The recess 152 extends partially into the first portion 44. The recess 152 extends partially into the second portion 50. The bottom 154 of the recess 152 defines a flat surface parallel to the contact surface 38. The bottom 154 of the recess 152 may function as a transition surface between the connection portion 22 and the transition portion 24. Thus, different from the previous embodiments, the transition surface, that is, 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 the 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 side walls 158, 160 extending along the longitudinal direction 100 respectively. The outer surfaces of the respective side walls 158, 160 correspond to a part of the outer peripheral wall 46. The transition portion 24 has a substantially U-shaped cross section up to at least 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 contribute to the transmission of current in the transition portion 24 in addition to the side walls 64, 66. Due to the characteristics of the recess 152, it is possible to reduce the material while ensuring sufficient current transmission in the transition portion 24.

[0098] The thickness 42 of the connection portion 22 may be smaller 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 shown in FIG. 7, the distance 170 between the side walls 64, 66 in the connection portion 22 is larger than the distance 172 between the side walls 158, 160, particularly 1.2 to 1.5 times larger. 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 characteristics 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] FIG. 8 schematically shows a cross-sectional view of a connector housing 200 including two electrical connectors 10. FIG. 8 shows only a partial view of the connector housing 200. Hereinafter, elements having the same reference numerals as those described above will not be described again, and the description made in the previous paragraphs will be referred to.

[0101] The connector housing 200 may be manufactured from plastic, in particular by a plastic injection molding process. The connector housing 200 comprises respective receiving portions 202 for receiving each contact pin 26 of the electrical connector 10. Each receiving portion 202 comprises an opening 204 through which the contact pin 26 is inserted, in particular in the longitudinal direction 100. The opening 204 may have a circular shape. The size of the opening 204 is complementary to the diameter of the contact pin 26, in particular 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 diameter larger than the opening 204. Thus, the insertion of the contact pin 26 in the longitudinal direction 100 can be prevented by abutment with the shoulder 34. Alternatively or in combination, a seal 12 arranged around the segment 36 may prevent the insertion of the contact pin 26 into a further receiving portion 202.

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

[0103] The housing 200 includes an interface 210 through which the electrical connector 10 is inserted. The interface 210 may be covered by a cover 212. The cover 212 includes locking lances 214 that 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 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 each of the housings 202, which are identical. The number of receiving portions 202 in the connector housing 200 is not limited. The connector housing 200 may be adapted to receive the electrical contact 80 according to the second embodiment. The connector housing 200 may be adapted to receive the electrical contact 90 according to the third embodiment. The connector housing 200 may be adapted to receive the electrical contact according to the fourth embodiment. The connector housing 200 may 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 adhesable to the conductor. Alternatively, the connection portion 22 may be configured such that at least one of the contact surface 38 and the side walls 64, 66 is weldable or adhesable to the conductor.

[0106] All of the embodiments described above are not limiting and serve as examples showing the features and advantages of the present invention. It is understood that all or some of the features described above may be combined in different ways. Note that the individual features described with respect to one embodiment may be combined with another embodiment.

Description of Reference Numerals

[0107] 1 Electrical contact according to the prior art 2 Contact portion 3 Connection portion 4 Transition part 5 Flat contact surface 6 End part 7 Conductor 10 Electrical contact according to the first embodiment 12 Seal 20 Contact part 22 Connection part 24 Transition part 26 Contact pin 28 Cap 30, 32 End parts of the contact pin 34 Shoulder part 36 Segment of the contact pin 38 Flat contact surface 40 Second surface of the connection part 42 Thickness of the connection part 43 Thickness of the first part 44 First part of the transition part 46 Outer peripheral wall 48 Transition surface 50 Second part of the transition part 52 First circular base 54 Second circular base 56 Inclined surface 58 Rounding 60 First locking surface 62 Second locking surface 64, 66 Side walls 67 Height of the side wall in the first part 68 Height of the side wall in the connection part 69 Thickness of the side wall in the connection part 70 Free edge part 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 Central axis in the longitudinal direction 140 Electrical contact according to the fourth embodiment 142 Flange 144 Support surface of the flange 150 Electrical contact according to the fifth embodiment 152 Recess 154 Bottom of the recess 156 Wall 158, 160 Side walls 170, 172 Distance between the side walls 200 Connector housing 202 Accommodation part 204 Opening 206 Tubular chimney 208 Peripheral part 210 Interface 212 Cover 214 Lock lance A1, A2, A3, A4 Cross-sections

Claims

1. An electrical contact (10), comprising: The electrical contact (10) comprises: a contact part (20), a connection part (22) with a flat contact surface (38) configured for electrical connection with an electrical conductor; a transition portion (24) arranged along the longitudinal direction (100) of the electrical contact (10) between the flat contact surface (38) and the contact portion (20); Equipped with at least one first side wall protruding from said flat contact surface (38) and extending at least along said transition portion (24) relative to said longitudinal direction (100) of said electrical contact (10); An electrical contact (10).

2. a second side wall, the two side walls being disposed opposite each other along the longitudinal direction (100) of the electrical contact (10); The electrical contact (10) of claim 1.

3. 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); An electrical contact (10) according to claim 1 or 2.

4. The flat contact surface (38) Laser welding, Ultrasonic welding, Electric resistance welding, Induction welding, or Cold bonding with conductive adhesive configured to form an electrical connection with the conductor. An electrical contact (10) according to any one of claims 1 to 3.

5. a transition surface (48) and at least one first locking surface (60), said first locking surface (60) being positioned substantially transverse to said flat contact surface (38), said transition surface (48) connecting said first locking surface (60) to said flat contact surface (38); An electrical contact (10) according to any one of the preceding claims.

6. The flat contact surface (38) is arranged parallel to and offset from the longitudinal center axis (110) of the contact portion (20). An electrical contact (10) according to any one of the preceding claims.

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

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

9. Characterized in that it is integrally formed as a single part, An electrical contact (10) according to any one of the preceding claims.

10. 10. An electrical contact (10) according to any one of claims 1 to 9 and an electrical conductor (7), in particular a conductor cable or a busbar, the electrical conductor (7) being welded or glued to the flat contact surface (38), in particular only to the flat contact surface (38). Connection assembly.

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