Plug-in connector, plug-in connector device and method for manufacturing a plug-in connector

Abstract

The plug-in connector for a flexible conductor membrane (20) with a membrane-insulated conductor (21) has a receiving area for the conductor membrane (20), the receiving area having a receiving direction (R). The plug-in connector (10) further has a first housing part (30) with at least one plug-in contact element to which a number of blades are electrically conductively connected, and a second housing part (40) with a receiving area. The first housing part (30) and the second housing part (40) are pressed into one another. The second housing part (40) has two spring elements (42, 43) which are arranged with a spring action on the left-hand side of the receiving direction (R) in the receiving area (41) and two spring elements (44, 45) which are arranged with a spring action on the right-hand side of the receiving direction (R) in the receiving area. In the plug-in connector device, the conductor membrane (20) is arranged in the receiving area such that at least one spring element (42, 43) presses against a first side of the conductor membrane (20) and at least one spring element (44, 45) presses against a second side of the conductor membrane (20), the second side being located opposite the first side.

Description

[Technical Field]

[0001] The present invention relates to a plug-in connector for a flexible conductor membrane. Furthermore, the invention relates to a method for manufacturing the plug-in connector and to a plug-in connector arrangement comprising the plug-in connector. [Background technology]

[0002] Flexible conductive films with film-insulated conductors are currently used in a wide range of applications in entertainment and consumer electronics, as well as in vehicle manufacturing. Conductor films are used particularly when highly flexible conductor structures are required with the lowest possible weight and limited space requirements. Flexible conductive films allow multiple separate strip conductors to be ordered and guided in parallel, and are also capable of large bending, allowing conductive connections between components located in extremely limited installation spaces. In vehicle manufacturing, such conductive films must also be able to withstand greater mechanical forces, such as vibration.

[0003] Here, the contact of the individual membrane-insulated conductors is of particular importance: particularly in vehicle construction, this contact must be stable and resistant to all kinds of temperature and environmental influences as well as external mechanical influences.

[0004] DE 10 2015 100 401 84 describes a plug-in connector for a flexible conductor membrane with a membrane-insulated conductor, having a plug-in connector housing in which at least one plug-in contact element is arranged. In the connection area, a blade electrically conductively connected to the at least one plug-in contact element can penetrate and secure the at least one membrane-insulated conductor, establishing electrical contact. The plug-in connector housing has two housing parts that can be pushed into each other. The first housing part holds the blades and at least one plug-in contact element electrically conductively connected thereto. The second housing part receives and holds the flexible conductor membrane. The second housing section further includes at least one blade holder that accommodates the blades. The interface is configured so that at least some of the blades bend toward the membrane-insulated conductor when the two housing sections are pressed together. Bending the blades exerts pressure on the contact area between the blades and the membrane-insulated conductor, thereby increasing the electrical contact area. At the same time, the blades are kept under constant tension within the plug-in connector housing. This ensures good electrical and gas-tight contact in the plug-in connector.

[0005] To receive the flexible conductor membrane into the second housing part, the membrane is inserted into the plug-in connector through the receiving opening. However, in this case, the conductor membrane has a large tolerance, which causes it to not always be held in the center of the connector housing. When the blade moves toward an improperly held conductor membrane to cut into it, the blade may cut into the edge region of the conductor. In this case, one part of the blade remains in electrical contact with the conductor, while another part simply passes through the insulating material of the conductor membrane. This impairs the electrical contact between the conductor and the plug-in contact element.

[0006] DE 199 20 981 A 1 describes an electrical connector. It has an insulator having openings at predetermined positions above a plurality of contacts for receiving connecting portions. A pressing portion is rotatably supported by the insulator. A locking assembly is used to lock the pressing portion to the insulator only when the locking portion is correctly positioned. A detection assembly detects improper positioning of the locking portion. The locking assembly has a locking portion formed on the insulator and an engaging protrusion formed on the pressing portion to engage with the locking portion. The detection assembly has a pair of locking arms formed on the insulator and a detection protrusion formed on the pressing portion. When a connecting portion is partially inserted between the locking arms, the locking arms are pressed outward and deformed, thereby preventing rotation of the pressing portion.

[0007] DE 11 2013 003 215 T5 describes a flexible, one-piece multi-wire plug-in connector, which has a pair of engaging hooks, each of which is formed on both widthwise end faces of a mounting surface and engages with a pair of engaging holes, each of which is opened on both widthwise end faces of a terminal part.

[0008] U.S. Patent No. 4,577,920 discloses a one-piece metal element for guiding cables into a shielded connector housing having a cable retention base from which cable locators project upwardly for locating various insulated conductors and cable sheaths therebetween. Summary of the Invention [Problem to be solved by the invention]

[0009] The object of the present invention is to provide a plug-in connector for a flexible conductor membrane with membrane-insulated conductors, in which the conductor membrane can be positioned with such precision that it is ensured that all blades of the plug-in connector always fully penetrate the conductors through the conductor membrane. It is a further object of the present invention to provide a method for producing such a plug-in connector, as well as a plug-in connector device comprising the plug-in connector and the flexible conductor membrane. [Means for solving the problem]

[0010] In a first aspect of the present invention, one of these problems is solved by a plug-in connector for a flexible conductor membrane with membrane-insulated conductors, which has a receiving area for the conductor membrane. The receiving area has a receiving direction. Here, the receiving direction is understood as the direction in which the conductor membrane can be pressed into the receiving area of ​​the plug-in connector from the outside of the plug-in connector. Spring or elastic elements are arranged in the receiving area so that they bounce perpendicular to the receiving direction. In particular, they are spring-biased perpendicular to the receiving direction. This has the effect that a conductor membrane inserted into the receiving area along the receiving direction is subjected to a spring force acting perpendicular to the receiving direction. This makes it possible to position the conductor membrane in a desired position perpendicular to the receiving direction. This eliminates the tolerance between the width of the conductive film and the width of the receiving area, so the receiving area can be configured to a width that allows the conductive film to be easily inserted, which can also accommodate conductive films of various widths as long as the positions of the conductors on the conductive film are the same for all conductive films.

[0011] The plug-in connector is configured with a first housing part and a second housing part. The first housing part has at least one plug-in contact element to which a plurality of blades are electrically conductively connected. The second housing part has a receiving area and a spring element. The housing parts are pressed together. This configuration of the plug-in connector allows the conductor membrane to be first inserted into the receiving area of ​​the second housing part, and then the housing parts are further pressed together, allowing the blades to move into the receiving area and penetrate the conductor membrane. In this case, spring elements in the receiving area allow the conductor membrane to be positioned in the receiving area so that it rests above the blades, each of whose conductors is connected to the same plug-in contact element, and the blades are each positioned in the center of the conductor, thereby ensuring that the blades penetrate only the conductor and do not cut into the insulating material at the edge of the conductor.

[0012] The receiving area is provided to press the front side of the conductor membrane along the receiving direction, while the rear side remains outside the plug-in connector. The plug-in connector has two spring elements arranged on the left side in the receiving direction and two spring elements arranged on the right side in the receiving direction. By exerting pressure on the conductor membrane at two different positions on each side, not only is the conductor membrane centered in the receiving area, but also prevents twisting of the conductor membrane's longitudinal axis relative to the receiving direction. In addition, the two spring elements on each side allow multiple contact of the conductor membrane. This means that centering is possible even if one of the spring elements is damaged.

[0013] If the plug-in connector has several spring elements, all spring elements are preferably equally spring-biased so that pressure is exerted evenly on the conductor membrane.

[0014] Furthermore, the receiving area preferably has a stop for the conductor membrane opposite the receiving opening for the conductor membrane. In this case, when the front side of the conductor membrane is guided into the receiving area through the receiving opening, it can only be pushed into the receiving area until the front side hits the stop. In order to enable visual confirmation of whether the conductor membrane has actually hit the stop, at least one opening through which the stop is visible is preferably arranged in the second housing part. The opening is particularly configured as a slot extending perpendicular to the receiving direction. Its length particularly corresponds to the width of the receiving area.

[0015] The spring element is preferably configured with spring arms that are arranged substantially parallel to the receiving direction. By substantially parallel, it is understood in particular that the longitudinal axes of the spring arms form an angle of at most 10 degrees with the receiving direction. Furthermore, the spring element has positioning elements that protrude from the spring arms perpendicular to the receiving direction into the receiving area. When the conductive membrane is inserted into the receiving area, the positioning elements cause the spring elements to contact the conductive membrane at a defined position. The spring arms are deflected relative to their longitudinal axes and exert a spring force on the conductive membrane.

[0016] In order to be able to achieve a high spring force without the risk of the spring arm breaking when the conductive membrane is inserted into the receiving area, the spring arm and the positioning element are preferably constructed as a one-piece solid cast part.

[0017] Even if the spring element can in principle be provided as a separate component in the plug-in connector, it is preferred to form it integrally with the plug-in connector. On the one hand, this simplifies the manufacture of the plug-in connector, and on the other hand, reduces the risk of tolerances in the position of the spring element. If the plug-in connector has two housing parts, the spring element is preferably formed integrally with the second housing part.

[0018] In a second aspect, the present invention relates to a method for manufacturing a plug-in connector according to the first aspect of the invention, in which the second housing part provided with the spring element is produced in a mould by a casting process. The casting process is in particular an injection moulding process. In the casting process, the mould is filled with a casting compound, in particular a plastic melt. In this process, the filling is carried out in such a way that the spring element is not filled at the end of the mould filling. By filling the part of the mould used to form the spring element at an early stage of the casting process and gating it at a different position of the housing part, a complete and uniform filling of this part of the mould is ensured. As a result, tolerances in the shape of the spring element that would result from uneven filling at this point can be eliminated, and such tolerances should be avoided, since the correct shape and positioning of the spring element are important for the accurate positioning of the conductor membrane in the plug-in connector.

[0019] In a third aspect, the present invention relates to a plug-in connector arrangement comprising a plug-in connector according to the first aspect of the invention and a flexible conductor membrane with membrane-insulated conductors. The conductor membrane is arranged in the receiving area so that at least one spring element presses against a first side of the conductor membrane, e.g., the left side, and at least one spring element presses against a second side of the conductor membrane opposite the first side, e.g., the right side. It is particularly preferred that the conductor membrane is pressed against the spring elements to be centered in the receiving area.

[0020] The conductive membrane is preferably guided through the receiving opening into the receiving area and strikes a stop opposite the receiving opening, the stop and spring element allowing for accurate positioning of the conductive membrane both along the receiving direction and perpendicular to the receiving direction.

[0021] Embodiments of the invention are illustrated in the drawings and are explained in more detail in the following description. [Brief explanation of the drawings]

[0022] [Figure 1a] 1 is an isometric view showing components of a plug-in connector arrangement according to an embodiment of the present invention in a first assembly step. [Figure 1b] 1 is a cross-sectional isometric view showing components of a plug-in connector arrangement according to an embodiment of the present invention in a first assembly step. [Figure 1c] 1 is a top view showing components of a plug-in connector arrangement according to an embodiment of the present invention in a first assembly step; [Figure 1d] 1 is an isometric cross-sectional view showing components of a plug-in connector arrangement according to an embodiment of the present invention in a first assembly step. [Figure 2] 1 is a top view of a spring element of a plug-in connector according to an embodiment of the present invention; FIG. [Figure 3a] 1 is an isometric view of a plug-in connector arrangement according to an embodiment of the present invention in a second assembly step. [Figure 3b]1 is a cross-sectional isometric view of a plug-in connector arrangement according to an embodiment of the present invention in a second assembly step. [Figure 3c] 10 is a top view of a plug-in connector arrangement according to an embodiment of the present invention in a second assembly step. FIG. [Figure 3d] 1 is an isometric cross-sectional view of a plug-in connector arrangement according to an embodiment of the present invention in a second assembly step. DETAILED DESCRIPTION OF THE INVENTION

[0023] 1a to 1d show a first assembly step of a plug-in connector arrangement according to an embodiment of the present invention. A plug-in connector 10 and a flat, flexible conductor membrane 20 with membrane-insulated conductors 21 are provided. The plug-in connector 10 has a first housing part 30 and a second housing part 40. A plurality of plug-in contact elements 31 are arranged in the housing part 30. Each plug-in contact element 31 is conductively connected to five blades 33 via a blade strip 32. The second housing part 40 has a receiving area 41 for the conductor membrane 20. This receiving area widens in a funnel-like manner towards the outside of the plug-in connector 10 to facilitate insertion of the conductor membrane 20.

[0024] The conductive membrane 20 may be inserted into the receiving area 41 along the receiving direction R. Two spring elements 42, 43 are arranged on the left-hand side of the receiving area 41 along the receiving direction R. Two further spring elements 44, 45 are arranged on the right-hand side of the receiving area 41 along the receiving direction R. The conductive membrane 20 is inserted into the receiving area 41 through a slot-shaped receiving opening 46. The receiving area 41 terminates in a stop 47 against which the conductive membrane 20 rests with its front side when pressed into the receiving area 41 through the receiving opening 46. The second housing part 40 has a slot-shaped opening 48 in its top surface through which the stop 47 is visible.

[0025] 2 shows one of the spring elements 42. It has a spring arm 421 arranged parallel to the receiving direction R in the receiving area 41. A positioning element 422 protrudes from one end of the spring arm 421 perpendicular to the receiving direction R into the receiving area 41 in the direction of the conductor membrane 20. The end of the spring arm 421 opposite the positioning element 422 is connected to the base of the second housing part 40. As a result, the spring element 42 is spring-biased. All elements of the second housing part 40, including the spring arms and positioning elements of all spring elements 42-45, are integrally formed from a plastic material.

[0026] 3a to 3d show a second assembly step of the plug-in connector device. The conductor membrane 20 is pushed into the receiving area 41 of the plug-in connector 10 until it contacts the stop 47, thereby supporting the conductor membrane 20 in the receiving area 41. It can be visually confirmed that the conductor membrane 20 is contacting the stop 47 through an opening 48, which allows visual confirmation of the contact of the conductor membrane with the stop 47. At this time, all of the spring elements 42 to 45 are each contacting a side of the conductor membrane 20 at one point. During this process, the positioning elements of the first two spring elements 42, 43 press against the left side of the conductor membrane 20, and the positioning elements of the other spring elements 44, 45 press against the right side of the conductor membrane 20. Before the conductive film 20 is inserted, the empty area in the receiving area 41 sandwiched by the positioning elements is slightly narrower than the conductive film 20. Therefore, when the conductive film 20 is inserted into the receiving area 41, the positioning elements move away from the conductive film 20, thereby deforming the spring arms of all of the spring elements 42 to 45 so that the conductive film 20 can be inserted into the receiving area 41. At this time, all of the spring elements 42 to 45 press the conductive film 20 with their spring forces, and position the conductive film 20 in the center of the receiving area 41. As a result, each strip conductor 21 is positioned accurately above the blade strip 32. In a third assembly step not shown, when the two housing parts 30, 40 are moved towards each other so that the blades 33 penetrate the conductive film 20, this ensures that each blade 33 penetrates the centre of one of the strip conductors 21.

[0027] The production of the two housing parts 30, 40 of the plug-in connector 10 may be carried out using an injection molding process. For this purpose, molten thermoplastic material is injected into a mold. When casting the second housing part 40, a gate is positioned so that all spring elements 42-45 are completely formed from the casting compound at the beginning of the mold filling, before the other areas of the second housing part 40 are formed.

Claims

1. A plug-in connector (10) for a flexible conductor membrane (20) having a membrane-insulated conductor (21), comprising a receiving area (41) for said flexible conductor membrane (20), said receiving area (41) having a receiving direction (R), in which: The plug-in connector (10) - a first housing part (30) comprising at least one plug-in contact element (31) to which a plurality of blades (33) are electrically conductively connected; - a second housing part (40) comprising said receiving area (41), The first housing part (30) and the second housing part (40) are pressed together, the second housing part (40) comprises two spring elements (42, 43) resiliently arranged on the left-hand side of the receiving area (41) in the receiving direction (R) and two spring elements (44, 45) resiliently arranged on the right-hand side of the receiving area (41) in the receiving direction (R), Each of the spring elements (42-45) comprises a spring arm (421) arranged substantially parallel to the receiving direction (R) and a positioning element (422) protruding from the spring arm (421) perpendicular to the receiving direction (R) into the receiving area (41). A plug-in connector (10) characterized in that:

2. The receiving area (41) comprises a stop (47) for the flexible conductive film (20) opposite a receiving opening (46) for the flexible conductive film (20), and at least one opening (48) through which the stop (47) is visible is arranged in the second housing part (40).

2. A plug-in connector (10) according to claim 1, characterized in that it is

3. The spring arm (421) and the positioning element (422) are constructed as a single solid cast part.

2. A plug-in connector (10) according to claim 1, characterized in that it is

4. The spring elements (42-45) are integrally formed with the second housing part (40) of the plug-in connector (10). A plug-in connector (10) according to any one of claims 1 to 3, characterized in that it

5. A method for manufacturing a plug-in connector (10) according to claim 4, comprising the steps of: the second housing part (40) with the spring elements (42-45) is manufactured in the mould by a casting process so that the spring elements (42-45) are not formed at the end of filling the mould with casting compound; method.

6. A plug-in connector (10) according to any one of claims 1 to 3 and a flexible conductor membrane (20) having a membrane-insulated conductor (21), the flexible conductive membrane is arranged in the receiving area (41) such that at least one spring element (42, 43) presses against a first side of the flexible conductive membrane (20) and at least one spring element (44, 45) presses against a second side of the flexible conductive membrane (20), the second side being opposite to the first side; Plug-in connector device.

7. The flexible conductive membrane (20) is centered in the receiving area (41) by the spring elements (42-45).

7. A plug-in connector arrangement according to claim 6, characterized in that it comprises:

8. A plug-in connector (10) according to claim 2 and a flexible conductor membrane (20) having a membrane-insulated conductor (21), the flexible conductive membrane is arranged in the receiving area (41) such that at least one spring element (42, 43) presses against a first side of the flexible conductive membrane (20) and at least one spring element (44, 45) presses against a second side of the flexible conductive membrane (20), the second side being opposite to the first side; The flexible conductive film (20) is guided through the receiving opening (46) into the receiving area (41) and comes into contact with a stop (47) on the opposite side of the receiving opening (46). A plug-in connector device comprising:

9. The flexible conductive membrane (20) is centered in the receiving area (41) by the spring elements (42-45).

9. A plug-in connector arrangement according to claim 8, characterized in that it comprises:

Images