Contact element and contact device

Abstract

To provide a contact element which guarantees that insertion force is not too high when a mating contact element is inserted and also guarantees that each contact reliably contacts in a direction orthogonal to an insertion direction.SOLUTION: A contact element 1 includes a connection part 2 formed to be connected to an electrical line 40; and a contact part 3 formed for the contact of a mating contact element 60. A thin piece group is arranged on the contact part 3. The thin piece group has at least two contact thin pieces 21. The contact thin pieces 21 of the thin piece group are bound to one common back element at respective first ends, and project from the back element along the substantially same direction.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a contact element and a contact element device.

[0002] Background Art For high contact safety of an electrical connector having a contact element and a mating contact element (so-called contact device), it is advantageous to provide as many contacts as possible for making electrical connection with the mating contact element (e.g., circular pin or flat blade) in a socket contact. These contacts are usually attached to springy contact lamellae, which press these contacts with a defined normal force adapted to the contact requirements and the load-bearing capacity of the contact surface against a corresponding contact formed, for example, as a flat blade. In this case, the spread of the contact lamellae usually runs along the longitudinal direction of the contact element and extends parallel to the insertion direction of the mating contact element.

[0003] According to German Patent Application Publication No. 102005043156, a socket contact is known which is provided with a plurality of contact lamellae each having one contact. In this case, the contacts of two contact lamellae are arranged one behind the other when viewed along the insertion direction. However, these contact lamellae have significantly different shape designs. Further, the contact lamellae having contacts arranged one behind the other each project from one respective back element in the opposite direction at the original thin plate portion, so that a time-consuming bending process is required.

[0004] Disclosure of the Invention The present invention starts from the recognition that the hitherto known configurations of contact elements having a plurality of contacts can only be manufactured extremely laboriously (by an additional bending process, see above). However, for the manufacture of contact elements, a manufacturing process as simple as possible is advantageous.

[0005] However, in the case of a simple means in which a plurality of contacts are provided in the form of "double protrusions" on the same contact lamella, with the contacts being arranged one behind the other (when viewed along the insertion direction), even a very small difference in the protrusion height is already sufficient in this case to change the normal force or to completely invalidate the smaller-formed contacts and make them no longer useful for current transmission. To avoid the mutual influence of the normal forces, it has been shown to be advantageous to provide contacts with their own spring arms without mechanical connections. Ideally, the springy lamellae have at least approximately the same shaped design.

[0006] Furthermore, the present invention starts from the recognition that the mutually adjacent arrangement of a plurality of contact lamellae each with their own contacts is limited by the width of the contact lamellae (which have to apply the corresponding (contact) forces), the punching gap between these contact lamellae, and the predefined width of the mating contact element (for example a flat blade). Furthermore, the mating contact element must be able to have a certain play in the contact element when inserted into the contact element. Thereby, due to the low insertion force, a large frictional force or even the occurrence of clamping should be achieved in the absence of tolerances (position and size) of the mating contact element and the contact element. Such play does not precisely define the position of the mating contact element in the contact element, but on the other hand it is desirable that all contacts have a reliable contact with the mating contact element at any position of the mating contact element (even when abutting against one of the side walls of the contact element).

[0007] Therefore, the contact body has sufficient space for attaching a plurality of thin sheets positioned adjacent to each other. However, there is a risk that one contact point of one contact thin sheet only contacts the edge or corner of the mating contact element at a predetermined position, or no longer contacts its surface at all. For example, the outer dimensions of a socket contact for a mating contact element with a blade width of 0.6 mm formed as a flat blade can be made approximately the same size as a socket contact for a mating contact element with a blade width of 1.2 mm formed as a flat blade. Thus, in this example, for a mating contact element formed as a 0.6 mm flat blade, two contact thin sheets can be attached adjacent to each other as is usually done with contacts for mating contact elements formed as 1.2 mm flat blades. However, in this case, reliable contact with the contact points of both contact thin sheets is not guaranteed at all insertion positions of the 0.6 mm mating contact element.

[0008] Therefore, it is necessary to provide a contact element into which a mating contact element can be inserted. This contact element should desirably be as easy to manufacture as possible. Furthermore, ideally, it should have a plurality of contact points arranged one behind the other when viewed along the insertion direction, and it is desirable that all contact points apply substantially the same contact force (normal force) to the inserted mating contact element. Additionally, for example, to keep the risk of tilting as small as possible, it should be guaranteed that the insertion force during insertion of the mating contact element is not too high. Moreover, regardless of the insertion position of the mating contact element, it is desirable that each contact point reliably contacts the surface of the inserted mating contact element (not just the edge or corner of the mating contact element) in a direction orthogonal to the insertion direction.

[0009] Advantages of the Invention This requirement can be covered by the subject matter of the invention according to the independent claims. Preferred embodiments of the invention are described in the dependent claims.

[0010] According to a first aspect of the invention, a contact element is proposed for inserting a mating contact element along an insertion direction.

[0011] The contact element has a connection portion formed for connection to an electrical line. The contact element further has a contact portion formed for contact with a mating contact element. A group of lamellae is arranged in the contact portion, the group of lamellae having at least two contact lamellae, the contact lamellae of the group of lamellae being each connected at a first end to a common back element and protruding from the back element along substantially the same direction, the contact lamellae of the group of lamellae extending parallel to the insertion direction for most of the extent of the contact lamellae (e.g., 50% or more). Each contact lamella has a contact portion with a contact point, which is formed to contact a mating contact element. The contact points of the contact lamellae of the group of lamellae are each oriented in a contact point direction substantially perpendicular to the insertion direction, and the contact point directions of the contact points of the contact lamellae of the group of lamellae form an angle of at most 45°, preferably at most 30°, with each other. The contact points of the contact lamellae of the group of lamellae are arranged one behind the other when viewed in the insertion direction.

[0012] In this case, by way of mere example, the contact points of the contact lamellae of the group of lamellae may have a predetermined spacing from each other when viewed along the x-direction perpendicular to the insertion direction, this spacing being at most 0.8 times the width of one contact lamella of the group of lamellae, preferably at most 0.7 times the width of one contact lamella of the group of lamellae, particularly preferably at most 0.5 times the width of one contact lamella of the group of lamellae, and most particularly preferably at most 0.3 times the width of one contact lamella of the group of lamellae.

[0013] As a further mere example, the contacts of the contact pads of the sheet group may have a predetermined spacing from each other when viewed along the x-direction perpendicular to the insertion direction, and this spacing is at most twice the diameter of the largest contact when viewed along the x-direction.

[0014] The contact pads of one sheet group are all arranged on the same back element and protrude in substantially the same direction, so that, preferably, the contact elements can be manufactured particularly simply. Furthermore, this results in a large number of contacts, in which case, since the contacts are assigned to different contact pads, the tolerance in the contact height also does not impair the normal force on the corresponding connector. By arranging the contacts successively along the insertion direction, preferably, compared to the contacts located adjacent to each other, an improved contact safety of the surface of the mating contact element is achieved that is independent of the position of the mating contact element in the direction orthogonal to the insertion direction. Such a tolerance in the position for the mating contact element in the direction orthogonal to the insertion direction reduces the possibility of tilting and thus preferably results in a reduction of the insertion force.

[0015] In the context of this application, in addition to the insertion direction, the following directions are distinguished: - the x-direction, which is perpendicular to the radial direction of a particular contact pad and extends perpendicular to the insertion direction when viewing the particular contact pad; - the radial direction, which is perpendicular to the insertion direction and, in the case of a non-circular contact but a rotationally symmetric contact chamber, is directed perpendicular to the x-direction; when the mating contact element is inserted into the contact element and thus a normal force or contact force acts along the radial direction, the contact pad is displaced along the radial direction; usually, the contact pad springs open radially outwards upon insertion of the mating contact element and then applies a contact force radially inwards.

[0016] When a flat blade is used as the mating contact element, a Cartesian coordinate system can be formed in the insertion direction, the radial direction, and the x-direction.

[0017] For example, if a circular contact is provided and the contact laminae are arranged circumferentially around the insertion direction, the x-direction is basically also the radial direction and can only be defined relative to one specific contact lamina. The contact spacing along the x-direction may be understood as the spacing along the radial direction.

[0018] The connection part may be formed for fixation and for electrical contact of an electrical line. The connection part may be formed, for example, as a crimp part. The electrical line may of course also be attached to the connection part, for example by soldering or welding.

[0019] The contact laminae may be formed from a material with good conductivity, for example copper, aluminum, or other metals.

[0020] The mating contact element may be formed, for example, as a blade contact, as a flat blade (for example having an aspect ratio (thickness to width) of at least 1:3), as a pin, as a circular pin, etc. The mating contact element may for example be a component of a corresponding connector.

[0021] The concept of "contact" should be understood as the area on the contact lamina that is formed between the contact lamina and the mating contact element during the normal insertion of the mating contact element of an electrical contact and on which a normal force to the mating contact element acts.

[0022] The lamina group may be provided with three or more contact laminae, for example three, four, five, or more contact laminae. Even when three or more contact laminae are provided, all the contacts of the contact laminae of the lamina group are positioned one after the other.

[0023] In this case, all the contacts of the contact lamellae may be positioned at relatively small intervals from each other when viewed along, for example, the x-direction (a direction orthogonal to the insertion direction) (measuring from the outermost contact on one side to the outermost contact on the other side, respectively, between the center points), and this interval may be smaller than, for example, 0.8 times the width of one contact lamella of the lamella group, preferably at most 0.7 times the width of one contact lamella of the lamella group, particularly preferably at most 0.5 times the width of one contact lamella of the lamella group, and extremely particularly preferably at most 0.3 times the width of one contact lamella of the lamella group.

[0024] It can be assumed that this interval is at most twice the diameter of the largest contact.

[0025] On the other hand, however, it is not necessary to include all the contact lamellae protruding from one common back element in one lamella group in the same direction. In this case, for example, when five contact lamellae protrude from one back element, only two of these contact lamellae can be included in one lamella group.

[0026] The contact element may have a contact box at the contact portion, and a lamella group is arranged inside this contact box. The contact element can have an insertion opening at its front end for inserting the mating contact element. This insertion opening can be arranged, for example, at the front end of the contact box.

[0027] The contact force or the normal force may be understood as the force applied from the contact lamella (through its contact point) to the surface of the mating contact element when inserting the mating contact element. The contact force or the normal force may be, for example, in the range of 0.5 N to 7 N for each contact lamella, preferably in the range of 1 N to 5 N, and may be, for example, 1 N or 2 N for each contact lamella.

[0028] The expression "substantially along the same direction" may be understood to mean that the angle between the contact lamellas is less than ±20° (especially with respect to the main extension direction).

[0029] The extension length of one contact lamella may be understood to be the length of the contact lamella along the insertion direction, measured from the point where the contact lamella is separated from the back element to the end furthest from the back element.

[0030] The contact lamellas of the lamella group are formed separated from each other, except for a common back element and possibly the other end of the contact lamella. In other words, the contact lamellas are spaced apart from each other or separated from each other.

[0031] The contact lamellas of the lamella group are each formed (in a cantilever manner) without being supported at the second end opposite the first end, whereby preferably a particularly large spring deflection of the contact lamella in the radially outer direction is obtained. More preferably, thereby, since each contact lamella is joined only at one location, the production is simplified. Even more preferably thereby, when the mating contact element is inserted at an angle, each contact lamella can bend individually or separately, thereby ensuring that a very high point load occurs on one side of the mating contact element and only a slight load or no load at all occurs on the other side.

[0032] A contact lamella that is joined at one end, guided at the second end, bent U-shaped here, returned towards the first end again, and joined there again is not "cantilevered" in the sense of this application because it is joined at both ends.

[0033] The contact portion of the contact lamella may be arranged, for example, at the free end of the contact lamella. For example, the length of the contact portion is at most 20%, preferably at most 15%, particularly preferably at most 10% of the total length of the contact lamella.

[0034] Due to the widths of the contact lamellas of the lamella group differing from each other by at most 25%, preferably, the spring forces of the contact lamellas are substantially the same. In other words, the normal forces acting on the mating contact element for each contact lamella are similar or substantially the same for each contact lamella. Thereby preferably, substantially the same electrical resistance of each contact lamella to the mating contact element can occur. Further thereby preferably, since substantially the same amount of material is always pressed when separated, the production of the lamella group is simplified and the tolerance of the thickness of the contact lamellas is well maintained.

[0035] Due to each contact lamella being consistently formed in the x - direction perpendicular to the insertion direction, preferably, the production of the lamella group is simplified.

[0036] In this case, the expression "consistently" means that the contact lamella is a member without holes or through - holes.

[0037] For example, it is assumed that each contact lamella, in particular, does not have a through - hole or is not separated in the region of the first end.

[0038] Due to at least two of the contact lamellas of the lamella group being directly adjacent to each other and coupled to the back element, preferably, the contacts of these at least two contact lamellas can be arranged in sequence particularly easily. Preferably thereby, the geometry of these at least two directly adjacent contact lamellas can be formed to be substantially the same.

[0039] In a further configuration, the contact element is formed as a socket contact element. Thereby, preferably, particularly good and reliable contact with the mating contact element is formed.

[0040] Alternatively or additionally, the contact element may be a punched and bent part. Thereby, particularly simple and inexpensive production of the contact element is possible. For example, the contact element may be formed from metal, for example, may mostly have copper or aluminum.

[0041] Since the contact is embossed in the contact lamina, preferably, particularly simple, inexpensive, and reproducible production of the contact is possible.

[0042] For example, it can be assumed that the contact is formed in a circular or oval or oblong or polygonal form or linearly.

[0043] For example, it can be assumed that all contacts are formed in the same way. However, it can be assumed that the contacts of different contact laminas have different shapes. For example, the contact may be formed in a (semi)circular shape (i.e., circular in plan view). Another configuration may be formed in an oval shape in plan view, for example, with an aspect ratio greater than 1:1.2.

[0044] Since the contacts of the contact laminas of the lamina group overlap when viewed along the insertion direction, preferably, even when the mating contact element is displaced in a direction orthogonal to the insertion direction (along the x - direction) with respect to the target position of the mating contact element, the contacts can particularly reliably contact the mating contact element.

[0045] The contact foils of the foil group extend parallel to each other along most (i.e., more than 50%) of the length of each contact foil (for example, when viewed along its main extension direction). This preferably results in a particularly small required space for the contact foils in the insertion direction's orthogonal direction (in the x-direction) in the contact element or in the contact box of the contact element. Thus, when the space provided in the direction orthogonal to the insertion direction is the same, the maximum number of contact foils can be arranged in the contact element without the contact foils contacting or crossing each other (except for the back element from which the contact foils originate).

[0046] In this case, the main extension direction is considered to be the direction along which most of the contact foil extends.

[0047] At least one contact portion of the contact foils of the foil group is formed by being bent with respect to the main extension direction of the contact foils. In this way, by a particularly simple means, the joints of at least two contact foils of the foil group can be arranged one after the other, and the distance between the joints in the direction orthogonal to the insertion direction (along the x-direction) can be made particularly small. More preferably in this way, the contact foils can have substantially the same geometric shaping, and in this case, at the same time, the normal force or contact force of all the joints with respect to the inserted mating contact element can be made substantially the same magnitude (for example, a deviation of less than 10%).

[0048] In this case, at least one contact portion may be bent by at least 30°, preferably at least 45°, particularly preferably at least 60°, and may be bent, for example, 45° or 90°.

[0049] Of course, the joints can be arranged one after the other without bending, but this will make the length of the contact foil, for example, longer than that in the bent configuration.

[0050] Advantageously, each contact blade of the blade group has a spring portion between the back element and the contact portion. In this case, the spring portions of the contact blades of the blade group are formed such that the same magnitude of displacement of the contact point of the contact blade in the radially outward direction (e.g., when inserting the mating contact element or when inserted in the normal insertion state) generates substantially the same magnitude of contact force (in this case, the tolerance between the contact force or the normal force may be, for example, ±10%). Thereby, advantageously, all contact points have substantially the same contact resistance with respect to the mating contact element to be inserted, so that one of the contact points (having the smallest contact resistance) is not overloaded or heated excessively by a high current, and thus does not wear out earlier. Thereby, advantageously, a reliable electrical connection with a low contact resistance is provided (the total resistance is obtained by the reciprocal of the sum of the reciprocals of the individual contact resistances of the contact points to the mating contact element according to Kirchhoff's law for the resistance of a parallel circuit).

[0051] The spring portion may extend, for example, along the insertion direction or the main extension length, or may extend from the contact portion as a starting point to the contact part. The spring portion generates the spring action of the contact blade acting in the radially outward or inward direction. The spring portion can be defined by the contact part. The material properties of the contact blade may change due to the contact point, and thus its spring constant may also change.

[0052] If a part of the contact blade is bent with respect to the main extension direction, a spring portion may be formed between the back element and the starting point of the bending.

[0053] Advantageously, the other contact lamella of the lamella group, which has a spring portion shorter than the spring portion of one contact lamella, has a smaller width (B1, B2) and / or a smaller thickness (D1, D2) than the one contact lamella having the longer spring portion and / or is formed from a material that is more flexible than the one contact lamella having the longer spring portion. Thereby, advantageously, by simply and slightly adapting the geometry of the spring portions of the contact lamellas, the normal force or contact force of the contacts acting on the mating contact element to be inserted can be made substantially the same magnitude.

[0054] For example, only the thickness may be different. Or only the width may be different. Or only the material may be different. However, all possible combinations of these parameters are also possible, and are merely listed below by way of example: different widths and thicknesses, different thicknesses and materials, different widths and materials, different widths, thicknesses and materials.

[0055] In a further configuration, the contact element has a plurality of lamella groups. Thereby, advantageously, the number of contacts can be increased by simple means.

[0056] In this case, by way of example only, the plurality of lamella groups may all be attached to the back element.

[0057] That is, it can be assumed that the contact lamellas of the plurality of lamella groups project from the same common back element. In this case, it is understood that the contact lamellas having contacts arranged one behind the other along a first line substantially parallel to the insertion direction belong to the first lamella group. Similarly, if another contact is located one behind the other substantially along a second line different from and / or spaced from the first line and parallel to the insertion direction, the contact lamella of this other contact belongs to another second lamella group different from the first lamella group.

[0058] At least two of the wafer groups are arranged facing each other when viewed along the radial direction when viewed in a direction perpendicular to the insertion direction. Preferably, contact forces are applied to two opposite sides of the surface of the inserted mating contact element, respectively. In this way, preferably, the mating contact element can be fixed to the contact element particularly reliably and continuously, for example, it can be firmly clamped. For example, preferably, the mating contact element can be centered in the contact element. Thereby, in the contact element, the position of the mating contact element in the defined radial direction (i.e., the direction orthogonal to the insertion direction) is achieved particularly simply and reliably. Thereby, more preferably, a particularly good electrical contact is obtained with a sufficiently defined slight contact resistance.

[0059] According to a second aspect of the present invention, a contact device is provided. This contact device has a contact element as described above. This contact device further has a mating contact element. In a state where the contact element and the mating contact element are completely assembled with each other, the contacts of the contact wafers of the wafer group are in contact with the mating contact element one after another when viewed along the insertion direction.

[0060] As a result, the contact tabs of one tab group are all arranged on the same back element and protrude in substantially the same direction, so that the contact device can preferably be manufactured particularly simply. Furthermore, this results in a large number of contacts, in which case the contacts are assigned to different contact tabs, so that the tolerances in the contact height also do not impair the normal force on the corresponding connector. By arranging the contacts in front of and behind each other when viewed along the insertion direction, preferably compared to the contacts located adjacent to each other, an improved contact safety of the surface of the mating contact element is achieved that is independent of the position of the mating contact element in the direction orthogonal to the insertion direction (for example, along the x-direction in the case of flat contacts). Such a tolerance in the position for the mating contact element in the direction orthogonal to the insertion direction reduces the possibility of tilting and thus preferably results in a reduction of the insertion force.

[0061] For example, the contacts of the contact tabs of the tab group each apply a contact force to the mating contact element in a direction orthogonal (radial direction) to the insertion direction, and the contact forces of different contacts are substantially the same. The contact forces of different contacts may differ from each other by a maximum of 10%. This preferably provides a particularly long-lasting and safe contact device with a low contact resistance, preventing a single contact (having the lowest contact resistance) from being overheated and thus prematurely worn.

[0062] Drawings Further features and advantages of the invention will be apparent to those skilled in the art from the embodiments described below with reference to the accompanying drawings, which should not be construed as limiting the invention.

Brief Description of the Drawings

[0063]

Figure 1

Figure 2a

Figure 2b

Figure 2c

Figure 2d

Figure 3a

Figure 3b

Figure 3c

Figure 3d

Figure 3e

Figure 3f

Figure 4

[0064] FIG. 1 shows a schematic perspective view of a contact device 100.

[0065] The contact device 100 has a contact element 1 and a mating contact element 60 that can be inserted along an insertion direction E into the contact element 1.

[0066] The contact element 1 shown merely as an example in this specification is formed as a socket contact element. This may be formed, for example, as a punched and bent product. This contact element may contain, for example, a metal as a material, or mostly may contain, for example, copper or aluminum or a copper alloy.

[0067] The radial direction R extends in a direction orthogonal to the insertion direction E. The x - direction extends into the plane of the figure perpendicular to the insertion direction E and perpendicular to the radial direction R.

[0068] The contact element 1 has a connection portion 2 formed for connecting to an electrical line 40. The electrical line 40 has an insulator 41 surrounding a conductor 42, for example, a copper - made litz wire. In the connection portion 2, in this embodiment, an insulating crimp 4 and a wire crimp 5 are arranged.

[0069] The contact element 1 further has a contact portion 3 formed for contact with a mating contact element 60. In the contact portion 3, a contact box 50 is arranged, and this contact box has an insertion opening 52 at its front end. Through this insertion opening 52, the mating contact element 60 can be inserted into the interior 54 of the contact box 50. In the interior 54, contact flakes 21 extending in the radial direction R (extending perpendicular to the insertion direction E) and facing each other are arranged. The contact flake 21 shown on the upper side in FIG. 1 is a part of the first flake group 20a, and the contact flake 21 shown on the lower side is a part of the second flake group 20b. Therefore, both flake groups 20a, 20b are arranged in the contact portion 3, and basically, the contact element 1 may be formed without the contact box 50 shown here.

[0070] Each of the two sheet groups 20a, 20b has at least two contact sheets 21 (in FIG. 1, for each sheet group 20a, 20b, only the contact sheets 21 facing the observer are visible, see FIGS. 3a to 3d for details). The contact sheets 21 of each sheet group 20a, 20b are each joined at a first end 22a, 22b to a common back element 23a, 23b (a first back element 23a, a second back element 23b), and project from this back element 23 along substantially (e.g., ±20°, preferably ±10°) the same direction. The contact sheets 21 of each sheet group 20a, 20b extend parallel to the insertion direction E for most of their extension lengths L1, L2 (e.g., exceeding 50%) (in this drawing, only the extension length L of the visible contact sheets 21 is shown). Each contact sheet 21 of the two sheet groups 20a, 20b has a contact portion 24 with a contact point 25 formed to contact a mating contact element 60. In this drawing, since the contact points 25 of the four contact sheets 21 project from the surface of the contact sheets, the four contact points 25 are visible. The contact points 25 of the contact sheets 21 of each sheet group 20a, 20b are directed in contact directions P1, P2 that are substantially (e.g., ±20°, preferably ±10°) perpendicular to the insertion direction E (not shown in this drawing for clarity, see FIG. 3f). In FIG. 1, the contact points 25 of the first sheet group 20a are directed downward along substantially (±20°, preferably ±10°) the radial direction R, and the similar contact points 25 of the second sheet group 20b are directed upward along substantially (±20°, preferably ±10°) the radial direction R (the radial direction R extends perpendicular to the insertion direction E). The contact directions P1, P2 of the contact points 25 of the contact sheets 21 of each sheet group 20a, 20b form an angle α of at most 45°, preferably at most 30°, with each other (see FIG. 3f). The contact points 25 of the contact sheets 21 of each sheet group 20a, 20b are arranged one behind the other when viewed in the insertion direction E.

[0071] As a mere example, in this embodiment, the contacts 25 of the contact laminae 21 of the lamina group 20 have an interval Δx between each other that is at most 0.8 times the width of the contact lamina 21 as seen in a direction perpendicular to the insertion direction E. In this embodiment, the interval Δx is at most twice the size of the maximum diameters DK1, DK2 of the largest contacts 25 (see FIG. 3e).

[0072] The contact laminae 21 of both lamina groups 20a, 20b each have one spring portion 26a, 26b, respectively, between the back element 23 and the contact portion 24, in this case as a mere example. The spring portions 26a, 26b of the contact laminae 21 of both lamina groups 20a, 20b are, in this case as a mere example, formed such that the same-sized displacement of the contacts 25 of the contact lamina 21 in the radially outward direction generates (substantially) the same contact force. This contact force may be adjusted, for example, during the insertion of the mating contact element 60, or is applied to the surface 62 of the mating contact element 60 when the mating contact element 60 is fully inserted.

[0073] From the contact box 50, locking lances 51 that are reversibly formed in a spring-elastic manner project outward. These locking lances are formed to perform primary locking with undercuts (not shown here) provided in a contact chamber of a connector (not shown here).

[0074] The contact laminae 21 of both lamina groups 20a, 20b are formed, in this case for example, such that they are not supported (in a cantilevered manner) at the second ends 27a, 27b opposite to the first ends 22a, 22b. Basically, the two ends 22a, 27a or 22b, 27b of the contact lamina 21 can also be joined by, for example, one common back element at each of the second ends 27a, 27b. Such a second back element is, for example, different from the first back elements 23a, 23b.

[0075] The contact point 25 may be embossed on the contact thin sheet 21. The embossing can be performed, for example, by an embossing process. In this case, the contact point 25 may be formed, for example, in a circular shape or an oval shape or an oblong shape or in the form of a polygon or linearly. In this drawing, for reasons of visibility in particular, it is formed in a circular shape (in a plan view), that is, in a substantially semi-circular shape in a three-dimensional form.

[0076] Figures 2a to 2d show schematic plan views of a first contact thin sheet 21a and a second contact thin sheet 21b of one thin sheet pair 20 of the contact element 1 according to the prior art and a mating contact element 60 as seen from the radial direction R. Each contact element 1 is shown with a central axis Z extending parallel to the insertion direction E and passing through the center of the contact element 1 or the contact box 50.

[0077] The contact thin sheets 21a, 21b of the thin sheet pair 20 are connected to a common back element 23 at the contact portion 3 and protrude from the common back element 23 in a direction opposite to the insertion direction E. The first contact thin sheet 21a has a first width B1, and the second contact thin sheet 21b has a second width B2. The two widths B1, B2 may be the same. The two contact thin sheets 21a, 21b have the same extension length L. The two contact thin sheets have a spring region 26 and a contact region 24 at its second end 27 that is not supported. One contact point 25 is formed in each contact region 24. The two contact thin sheets 21a, 21b are separated from each other between the first end 22 and the second end 27.

[0078] The number of contact thin sheets 21 that can be located adjacent to each other (along the x direction) in the contact element 1 or in the contact box 50 of the contact element 1 may depend, for example, on the width BKE of the contact element 1 (along the x direction). This width of the contact element 1 may depend, for example, on the width BGK of the mating contact element 60 (along the x direction).

[0079] In FIG. 2a, a contact device 100 composed of a contact element 1 and a mating contact element 60 is shown in a state where the contact element and the mating contact element are not assembled to each other. The mating contact element 60 is arranged in the middle with respect to the central axis Z in terms of its width BGK. It can be seen that the width BKE of the contact element 1 is larger than the width BGK of the mating contact element 60. This is useful, for example, to prevent tilting when inserting the mating contact element 60 and thereby increasing the insertion force. The width BKE of the contact element 1 can also be formed for mating contact elements 60 with different widths BGK.

[0080] The mating contact element 60 has a surface 62 and an edge 61.

[0081] FIG. 2b shows the contact device 100 of FIG. 2a in a state where the contact element 1 and the mating contact element 60 are assembled. Both contacts 25 are in contact with the surface 62 of the mating contact element 60 and are located at a sufficient distance from the edge 61 of the mating contact element.

[0082] In FIG. 2c, a contact device 100 composed of a contact element 1 and a mating contact element 60 is shown in the same manner as in FIG. 2a (in a state where the contact element and the mating contact element are not assembled to each other). Different from FIG. 2a, the mating contact element 60 is no longer arranged in the middle with respect to the central axis Z in terms of its width BGK, but is shifted to the right along the x - direction (almost up to the side wall 56 of the contact box 50).

[0083] Figure 2d shows the contact device 100 of Figure 2c with the contact element 1 and the mating contact element 60 assembled. Due to the mating contact element 60 being shifted to the right (with respect to the central axis Z), only the contact point 25 of the second contact lamella 21b is still in contact with the surface 62 of the mating contact element 60. The contact point 25 of the first contact lamella 21a is not in contact with anything (although it may be in a state where the contact point is in contact with the edge 61 of the mating contact element 60, but in that case, a complete contact force cannot be applied).

[0084] Therefore, the number of contact points 25 in contact with the mating contact element 60 is reduced from the ideal state.

[0085] Figures 3a - 3d show schematic plan views of the first contact lamella 21a and the second contact lamella 21b (hereinafter also referred to as the contact lamella 21 when distinction is not necessary) of one lamella pair 20 of the contact element 1 and the mating contact element 60 as seen from the radial direction R. This may be, for example, a part of the contact device of Figure 1.

[0086] Both contact lamellae 21 of the lamella group 20 are directly adjacent to each other and are coupled to the back element 23. In another embodiment, three or more contact lamellae 21 may be assigned to the lamella group 20. In this case, for example, at least two of the contact lamellae of the lamella group may be directly adjacent to each other and coupled to the back element 23.

[0087] The contact lamellae 21 of the lamella pair 20 are coupled to a common back element 23 at the contact portion 3 and protrude from the common back element 23 in a direction opposite to the insertion direction E.

[0088] However, basically, the contact lamella 21 may protrude from the back element 23 along the insertion direction E. In this case, the back element 23 is arranged at the lower end of Figures 3a - 3d.

[0089] The contact 25 of the first contact wafer 21a has a first diameter DK1, and the contact 25 of the second contact wafer 21b has a second diameter DK2.

[0090] It can be seen that the contacts 25 of the contact wafers 21 of the wafer group 20 are arranged one behind the other when viewed in the insertion direction E.

[0091] Furthermore, the contacts have an interval Δx from each other that is at most 0.8 times the maximum of the respective widths B1, B2 of the contact wafers 21 when viewed in a direction perpendicular to the insertion direction E (along the x-direction). In this case, both widths B1, B2 are approximately the same size. In this embodiment, the interval Δx is smaller than 0.3 times the width B1, B2 of the contact wafers 21. In this figure, the interval Δx is, merely by way of example, even up to 2 times the maximum of the diameters DK1, DK2 of the largest contacts 25 for the sake of clarity which can show a slight interval Δx.

[0092] However, in order to provide different insertion trajectories for each contact 25, it may also be advantageous to configure the interval Δx to be somewhat larger than shown here. In this case, the interval Δx is, for example, in the range from 2 times the diameters DK1, DK2 of the contacts 25 to 0.8 times the width B of the contact wafers 21, preferably in the range from 2 times the diameters DK1, DK2 of the contacts 25 to 0.7 times the width B of the contact wafers 21, particularly preferably in the range from 3 times the diameters DK1, DK2 of the contacts 25 to 0.5 times the width B of the contact wafers 21, and extremely particularly preferably in the range from 3 times the diameters DK1, DK2 of the contacts 25 to 0.3 times the width B of the contact wafers 21.

[0093] Merely by way of example in this embodiment, it is also assumed that the contacts 25 of the contact wafers 21 of the wafer group 20 overlap (at least partially) when viewed in the insertion direction E.

[0094] In this figure, as an example, it can be seen that the first length L1 of the first contact tab 21a is longer than the second length L2 of the second contact tab 21b. In this case, the first spring portion 26a of the first contact tab 21a may be formed longer than the second spring portion 26b of the second contact tab 21b. However, basically, such a difference in length as an example may be brought about by, for example, contact portions 24 having different lengths. There may be no difference in length at all. This configuration may be possible, for example, by different separation positions in the common back element 23.

[0095] Furthermore, in this case, for example, it is assumed that the contact tabs 21 of the tab group 20 extend parallel to or along the insertion direction E, when viewed along the main extension direction along which they extend, and extend parallel to each other along most of the respective lengths L1, L2 of the contact tabs.

[0096] For example, it is assumed that at least one (in this case, both) of the contact portions 24 of the contact tabs 21 of the tab group 20 is formed by being bent with respect to the main extension direction of the contact tab 21. In this embodiment, each contact portion 24 is bent by, for example, about 45° in the direction of the other contact tab 21 with respect to the spring portion. Preferably, the bend is at least 30°. In this way, the possible difference in length of the spring portion 26 can be kept particularly small.

[0097] However, the contact points 25 can also be arranged one after the other without bending the contact portion 24.

[0098] Figure 3a shows a contact device 100 consisting of a contact element 1 and a mating contact element 60, with the contact element and the mating contact element not assembled with each other. The mating contact element 60 is centered with respect to the central axis Z in terms of its width BGK. It can be seen that the width BKE of the contact element 1 is larger than the width BGK of the mating contact element 60. This helps, for example, to prevent tilting when inserting the mating contact element 60 and thereby increasing the insertion force. The width BKE of the contact element 1 can also be formed for mating contact elements 60 with different widths BGK.

[0099] The mating contact element 60 has a surface 62 and an edge 61.

[0100] Figure 3b shows the contact device 100 of Figure 3a with the contact element 1 and the mating contact element 60 assembled. The two contacts 25, which are located one behind the other and overlap (slightly shifted in the x direction) when viewed along the insertion direction, are in contact with the surface 62 of the mating contact element 60 and are located at a sufficient distance from the edge 61 of the mating contact element.

[0101] Figure 3c shows a contact device 100 consisting of a contact element 1 and a mating contact element 60, similar to Figure 3a (with the contact element and the mating contact element not assembled with each other). Different from Figure 3a, the mating contact element 60 is no longer centered with respect to the central axis Z in terms of its width BGK and is shifted to the right (almost up to the side wall 56 of the contact box 50) along the x direction.

[0102] Figure 3d shows the contact device 100 of FIG. 3c with the contact element 1 and the mating contact element 60 assembled. Different from FIG. 2d, although the mating contact element 60 is shifted to the right (with respect to the central axis Z), each contact 25 of the contact laminae 21a, 21b is in contact with the surface 62 of the mating contact element 60. Both contacts 25 can press the surface 62 of the mating contact element 60 with contact forces or normal forces of substantially the same magnitude (e.g., with a maximum difference of ±10%).

[0103] Therefore, the number of contacts 25 in contact with the mating contact element 60 is not reduced from the ideal position of the mating contact element 60 in the ideal state (in this case, the middle with respect to the central axis Z).

[0104] Figure 3e shows an enlarged view of the contact portion 24 of both contact laminae 21 of FIG. 3a.

[0105] The distance Δx between both contacts 25 can be clearly seen. In this case, both contacts 25 overlap each other at their outermost portions.

[0106] Furthermore, it can be seen that the second contact lamina 21b of the lamina group 20 having a spring portion 26b shorter than the spring portion 26a of the first contact lamina 21a has a second width B2 smaller than the first contact lamina 21a having the longer spring portion 26a and / or a second thickness D2 smaller than the first contact lamina 21a and / or is formed of a material more flexible than the first contact lamina 21a having the longer spring portion 26a. In this way, for example, the spring constants of both contact laminae 21a, 21b resulting from different extension lengths L1, L2 or different lengths of the spring portions 26a, 26b can be made equal to each other. Thereby, for example, it can be ensured that the normal forces or contact forces of both contacts 25 are of substantially the same magnitude or deviate from each other by at most 10%, for example.

[0107] Figure 3f shows an enlarged perspective view of the contact portion 24 of both contact flakes in Figure 3a. It can be seen that the contact points (the first contact point 25a and the second contact point 25b) are embossed in the material of the contact flake 21. Further, the first contact direction P1 of the first contact point 25a and the second contact direction P2 of the second contact point 25b are shown (each as the normal to the plane of the highest point). Since both contact flakes 21a, 21b are slightly inclined to each other, in this case, the two contact directions P1, P2 form a predetermined angle α of about 10°. Ideally, the angle α = 0°, preferably the angle α is less than 45°, and particularly preferably less than 30°. In the case of circular contacts, it is usually possible that the angle α is not 0°. This depends on the number of contact flakes 21 in one circular segment of the circular contact.

[0108] Figure 4 shows a schematic plan view of two flake groups 20 of one contact element 1 and a mating contact element 60 as seen along the radial direction R.

[0109] In this embodiment, two flake groups 20 each having two contact flakes 21 protrude from one common back element 23.

[0110] The outer contact flakes 21 of both flake groups 20, when viewed along the x-direction, each have a length longer than that of the inner contact flake 21 and are bent 90° inward at their contact portion 24. In this way, in this embodiment, two groups of contact points 25 positioned one after the other are formed (a first axis A1 is shown passing through the first group of both groups, and a second axis A2 is shown passing through the second group).

[0111] It can be seen that each contact point belonging to one flake group 20 may be arranged slightly offset from each other along the x-direction. These contact points form different insertion tracks on the mating contact element 60.

[0112] The mating contact element 60 is shown in the non-inserted state. One is the central position (ideal position) where the mating contact element is aligned in the middle with respect to the central axis, which is shown (by the solid line). The other is that it is shifted by a deviation ΔA to the right along the x direction from the ideal position, and a state where it is not yet in contact with the right side wall 56 of the contact box 50 is shown. At both positions of the mating contact element 60, when the mating contact element 60 is inserted into the contact element 1, it is clearly shown that all the contacts 25 can contact the surface 62 of the mating contact element 60.

[0113] Also at the same time, if four contact flakes 21 configured in the same shape are arranged adjacent to each other along the x direction, it can be seen that if the mating contact element 60 is not in the central position, the contacts 25 of at least the leftmost contact flake 21 will no longer contact the surface 62 of the mating contact element 60.

[0114] Finally, it is stated that the contact element 1 or the mating contact element 60 or the contact device 100 is suitable or can be suitable or is assumed or can be assumed for use or application in, for example, an automobile or in an inverter, a motor, a control device, a battery, a charger, or a generator. However, the contact element 1 or the contact device 100 or the connector or the connector device is not limited to such use or application.

Claims

1. A contact element for inserting a mating contact element (60) along an insertion direction (E), wherein the contact element (1) comprises: a connection portion (2) formed for connection to an electrical line (40); a contact portion (3) formed for contact with the mating contact element (60); and has: a group of laminae (20) arranged in the contact portion (3); the group of laminae (20) having at least two contact laminae (21); the contact laminae (21) of the group of laminae (20) being joined at a first end (22) to a common back element (23) and protruding from the back element (23) along the same direction; the contact laminae (21) of the group of laminae (20) extending parallel to the insertion direction (E) for most of the extension length (L1, L2) of the contact laminae (21); each contact lamina (21) having a contact portion (24) with a contact point (25) formed to contact the mating contact element (60); the contact points (25) of the contact laminae (21) of the group of laminae (20) being directed in a contact point direction (P1, P2) perpendicular or nearly perpendicular to the insertion direction (E); the contact point directions (P1, P2) of the contact points (25) of the contact laminae (21) of the group of laminae (20) forming an angle (α) of at most 45° or at most 30° with each other; the contact points (25) of the contact laminae (21) of the group of laminae (20) being arranged in front and behind each other as seen along the insertion direction (E); the contact points (25) of the contact laminae (21) of the group of laminae (20) having a predetermined spacing (Δx) from each other as seen along the x - direction perpendicular to the insertion direction (E), the spacing being at most 0.8 times or 0.7 times the width (B) of one contact lamina (21) of the group of laminae (20); the contact laminae (21) of the group of laminae (20) each having a spring portion (26) between the back element (23) and the contact portion (24); The spring portion (26) of the contact thin sheet (21) of the thin sheet group (20) is formed such that the same magnitude displacement of the contact point (25) of the contact thin sheet in the radially outer direction generates the same magnitude contact force, and is a contact element. The contact element according to claim 1, wherein the other contact thin sheet (21) of the thin sheet group (20) having a spring portion (26) shorter than the spring portion (26) of one contact thin sheet (21) has a smaller width (B1, B2) and / or a smaller thickness (D1, D2) than the one contact thin sheet (21) having the longer spring portion (26) and / or is formed of a material more flexible than the one contact thin sheet (21) having the longer spring portion (26). A contact element for inserting a mating contact element (60) along an insertion direction (E), wherein the contact element (1) has a connection portion (2) formed for connection to an electrical line (40), and a contact portion (3) formed for contact with the mating contact element (60), and a thin sheet group (20) is arranged in the contact portion (3), the thin sheet group (20) has at least two contact thin sheets (21), the contact thin sheets (21) of the thin sheet group (20) are each joined to a common back element (23) at a first end (22) and project from the back element (23) along the same direction, the contact thin sheets (21) of the thin sheet group (20) extend parallel to the insertion direction (E) for most of the extension length (L1, L2) of the contact thin sheets (21), each contact thin sheet (21) has a contact portion (24) provided with a contact point (25) formed to contact the mating contact element (60), the contact points (25) of the contact thin sheets (21) of the thin sheet group (20) are each directed in a contact point direction (P1, P2) perpendicular or nearly perpendicular to the insertion direction (E). The contact directions (P1, P2) of the contacts (25) of the contact laminae (21) of the lamina group (20) form an angle (α) of at most 45° or at most 30° with each other. The contacts (25) of the contact laminae (21) of the lamina group (20) are arranged one behind the other when viewed along the insertion direction (E). The contacts (25) of the contact laminae (21) of the lamina group (20) have a predetermined spacing (Δx) from each other when viewed along the x-direction perpendicular to the insertion direction (E), the spacing being at most 0.8 times or 0.7 times the width (B) of one contact lamina (21) of the lamina group (20). Each contact portion (24) of each contact lamina (21) is bent with respect to the main extension direction of the contact lamina (21) such that the contact portions (24) are one behind the other when viewed along the insertion direction (E) and approach each other in the x-direction perpendicular to the insertion direction. Each contact (25) is a contact element arranged at the bent portion of each contact portion (24).

4. The contact laminae (21) of the lamina group (20) are each formed without being supported at a second end portion (27) opposite the first end portion (22), the contact element according to any one of claims 1 to 3.

5. The widths (B1, B2) of the contact laminae (21) of the lamina group (20) differ from each other by at most 25%, the contact element according to any one of claims 1 to 4.

6. Each contact lamina is formed without any holes or through-holes consistently in the x-direction perpendicular to the insertion direction (E). The contact element according to any one of claims 1 to 5.

7. At least two of the contact laminae (21) of the lamina group (20) are directly adjacent to each other and joined to the back element (23), the contact element according to any one of claims 1 to 6.

8. The contact element (1) is formed as a socket contact element. and / or The contact element (1) is a punched and bent part. The contact element according to any one of claims 1 to 7.

9. The contact point (25) is embossed within the contact thin sheet (21). The contact element according to any one of claims 1 to 8.

10. The contact point (25) of the contact thin sheet (21) of the thin sheet group (20) overlaps when viewed along the insertion direction (E). The contact element according to any one of claims 1 to 9.

11. The contact thin sheets (21) of the thin sheet group (20) extend parallel to each other along most of each length (L1, L2) of the contact thin sheet (21). The contact element according to any one of claims 1 to 10.

12. At least one of the contact portions (24) of the contact thin sheet (21) of the thin sheet group (20) is formed by being bent with respect to the main extending direction of the contact thin sheet (21). The contact element according to any one of claims 1 to 11.

13. The contact element (1) has a plurality of thin sheet groups (20). The plurality of thin sheet groups (20) are all attached to the back element (23). The contact element according to any one of claims 1 to 12.

14. At least two of the thin sheet groups (20) are arranged facing each other when viewed in a direction perpendicular to the insertion direction (E). The contact element according to any one of claims 1 to 13.

15. A contact device, The contact element (1) according to any one of claims 1 to 14, A mating contact element (60), and having, In a state where the contact element (1) and the mating contact element (60) are completely assembled to each other, the contact points (25) of the contact thin sheets (21) of the thin sheet group (20) are in contact with the mating contact element (60) one after the other when viewed along the insertion direction (E). The contact points (25) of the contact thin sheets (21) of the thin sheet group (20) apply contact forces to the mating contact element (60) in a direction orthogonal to the insertion direction (E), and the contact forces of the different contact points (25) differ from each other by at most 10%. Contact device.

Images