Electrical contacts for forming electrical connections with electrical conductors

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 an electrical conductor, such as a connector cable or bus bar. The present invention also relates to a connection assembly comprising the electrical contact and the electrical conductor. [Background technology]

[0002] In most applications, it is desirable to provide a stable and durable electrical connection between the electrical contacts and the connector cable or busbar. Ultrasonic welding, electric resistance welding, and induction welding are known methods for welding electrical contacts to the connector cable or busbar. Ultrasonic welding is a welding process that uses high-frequency vibration energy. Unlike electric resistance welding, it is a solid-state welding process that does not melt the material being welded. Electric resistance welding is performed using a strong electric current under pressure. In induction welding, heat is electromagnetically induced in the electrical contacts.

[0003] For example, in the automotive industry, it is desirable to provide electrical contacts with high current carrying capacity, particularly for charging electric vehicles. Low current carrying capacity can cause undesirable overheating of the electrical contacts.

[0004] An electrical contact known in the prior art is shown in FIG. 1. The electrical contact 1 of FIG. 1 comprises a contact portion 2, a connection portion 3, and a transition portion 4 located between the contact portion 2 and the connection portion 3 along the longitudinal direction 100 of the electrical contact 1. The connection portion 3 comprises a flat contact surface 5. An end 6 of a conductor 7 is welded to the flat contact surface 5 by ultrasonic welding. A cross-section (A) transverse to the longitudinal direction 100 shows that the cross-section of the electrical contact 1 at this point corresponds to the sum of the cross-section A1 of the end 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 a cross-section (B) transverse to 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 decreases by approximately 50% between cross-sections (A) and (B).

[0005] Too small a cross section at the transition is undesirable as it may not allow sufficient transmission of current, especially high voltage direct current. Summary of the Invention [Problem to be solved by the invention]

[0006] SUMMARY OF THE INVENTION It is an object of the present invention to provide an electrical contact for improved electrical connection compared to the prior art. [Means for solving the problem]

[0007] The object of the invention is realized by an electrical contact comprising a contact part, a connecting part with a flat contact surface configured for electrical connection with an electrical conductor, and a transition part arranged along a longitudinal direction of the electrical contact between the flat contact surface and the contact part, wherein at least one first side wall projects from the flat contact surface and extends at least along the transition part relative to the longitudinal direction of the electrical contact.

[0008] The sidewall features allow for an increased cross section of the transition. The increased cross section allows for a reduced electrical resistance. The reduced resistance allows for avoiding overheating of the electrical contacts during the passage of current. Thus, the transition is better adapted to the passage of strong currents.

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

[0010] Since the transition is not configured to receive electrical conductors, increasing the cross section at the transition is particularly advantageous as the electrical conductors do not contribute to the cross section at this point.

[0011] Since the cross section of the conductor contributes to the overall cross section at the connection, the increased cross section at the transition advantageously allows for a reduction in the cross section at the connection. The reduction in the cross section of the connection allows for a reduction in the thickness of the connection, particularly at the flat contact surfaces. A thinner flat contact surface is advantageous, for example, to facilitate certain welding processes and / or allow for material savings.

[0012] In particular, the contact surface of the connection is limited to a planar surface, i.e., a surface that completely contains a line passing through two of its points.

[0013] The side walls may be integrally connected to the transition section. The side walls may project at an angle relative to the flat contact surface, in particular at an angle between 45° and 135°, more particularly at an angle between 80° and 95°. The side walls may project perpendicular to the flat contact surface, i.e. at an angle of 90°. The side walls may thus be parallel to the side surfaces of the busbar, for example. This may facilitate welding or gluing between the parallel surfaces of the side walls and the side surfaces of the busbar.

[0014] In particular, the electrical contacts are configured for electrical connection by a welding process with bus bars that are provided with insulating or non-insulating coatings.

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

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

[0017] According to one embodiment, the electrical contact may include a second sidewall, and the two sidewalls may be disposed opposite 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.

[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 symmetrical to each other along the longitudinal direction.The electrical contacts can be easily formed by a cold forming process.

[0021] At least one cross section of the connection and / or transition section may have a "U" shape. The "U" shape refers to the shape of the letter "U" in the Latin alphabet, with the central part of the "U" being flat to accommodate the flat contact surface. This particular geometry allows for an increased mechanical strength of the electrical contact, which is particularly advantageous, for example, for better resistance to vibrations induced by ultrasonic welding. Ultrasonic welding may in fact involve frequencies between 20 and 70 kHz, which cause strong mechanical vibrations in the electrical contact.

[0022] According to one embodiment, the largest cross section of the electrical contact at the connection section is equal to or smaller than the smallest cross section of the transition section, in particular the largest cross section of the electrical contact at the connection section is strictly smaller than the smallest cross section of the transition section, thus allowing the electrical contact to be thinner at the connection section.

[0023] At least one portion of the transition section may protrude from the contact section and the connection section. The at least one protrusion may form, for example, a support or a locking surface, respectively, against which the connector housing may 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 disc-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. Indeed, it may be necessary to monitor the temperature of the electrical contacts, especially when dealing with electrical contacts used to charge electric vehicles at charging bases. Alternatively or in combination, the first part may provide a surface adapted to hold the electrical contacts during the ultrasonic welding process.

[0025] According to one embodiment, the flat contact surface may be configured to form an electrical connection with the electrical conductor by laser welding, ultrasonic welding, electrical resistance welding, induction welding, or cold bonding with a conductive adhesive. Because 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 contacts may be configured to form an electrical connection without a crimping process.

[0027] According to one embodiment, the electrical contact may comprise a transition surface and at least one first locking surface, the first locking surface being positioned substantially transverse to 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, in particular two side walls. The transition surface may be a flat surface. The transition surface may be formed by a downward slope from the transition to the flat contact surface. Alternatively, the transition surface may be a curved surface or may be at least partially curved. The transition surface may be convex. The transition surface may be concave. This allows for material savings.

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

[0030] The locking surface may be formed by a protrusion of the transition portion, in particular by a protrusion of the first part of the transition portion. 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 central longitudinal axis of the contact portion, thereby allowing the central longitudinal axis of the electrical conductor to be connected to the contact surface to be aligned with the central longitudinal axis of the contact portion. By aligning the central longitudinal axis of the electrical conductor with the central longitudinal axis of the contact portion, a more compact electrical contact can be obtained. This alignment allows the size of the cavity in the sealing element in which the electrical conductor can be received to be reduced.

[0032] According to one embodiment, the height of the sidewalls from the flat contact surface may vary, at least partially increasing, in the direction from the connection portion to the contact portion, which allows for a reduced height of the sidewalls compared to sidewalls with a constant height, thus saving material for forming the electrical contacts.

[0033] Alternatively, the height of the sidewalls from the flat contact surface may be constant in the direction from the connection area to the contact area, which allows for a uniform increase in mechanical strength along the longitudinal direction.

[0034] The contact portion may be configured to be plugged into a mating electrical connector. The contact portion may be male or female. A male contact portion may be a pin. A female contact portion may have 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 multiple metal coatings of the same composition. Alternatively, the contact pin may have multiple metal coatings with different compositions. As an example, the contact pin may have a silver coating and a nickel underlayer. The contact pin may have a galvanic coating including silver, gold, or tin. The ends of the contact portions may be provided with caps. The caps protect the ends of the contact pins and reduce the risk of contact. Thus, the caps provide finger protection, more commonly known as "touch-safe." The caps may be removably placed on the contact portions. The caps may be made of a dielectric material, for example, a plastic material.

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

[0036] According to one embodiment, the electrical contacts may be integrally formed as a single part, thereby eliminating an assembly step. The electrical connector may be formed from a conductive material. The electrical connector may be formed from a metallic material. The electrical connector may be formed by a cold forming process. The electrical contacts may be made from copper or a copper alloy, particularly a copper alloy with a high copper content. The use of copper is advantageous due to its very good electrical conductivity. The electrical contacts may be made from aluminum or iron.

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

[0038] In particular, the conductor cable or busbar may be welded or glued only to the flat contact surface. The connection assembly may be characterized by the absence of a weld between at least one sidewall 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 positioned in the connection section such that each sidewall is spaced apart from the conductor cable or busbar. The maximum distance between the first and second sidewalls 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 and second sidewalls may be greater than the diameter of the first portion of the transition section. The first portion may be a cylindrical solid portion.

[0039] Alternatively, the conductor cable or busbar may be welded or glued to both the flat contact surface and at least one side wall, in particular both side walls. This advantageously allows for an increased contact area 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 central longitudinal axis of the conductor cable or busbar may be aligned with the central longitudinal axis of the contact portion, which advantageously allows the bulk of the connection assembly to be reduced, and this alignment can be used to reduce the size of the cavity in the sealing element in 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 include at least one flat side. 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 with at least one flat side, more particularly a busbar of rectangular cross section.

[0043] The conductor cable may comprise a plurality of conductor metal strands, for example made of copper. The conductor cable may have a substantially circular cross section before welding. The portion of the conductor cable that is 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 realized by an electrical contact comprising a contact portion, a connecting portion with a contact surface configured for electrical connection with an electrical conductor, and a transition portion arranged along a longitudinal direction of the electrical contact between the contact surface and the contact portion, wherein at least one first side wall projects from the contact surface and extends at least along the transition portion relative to the longitudinal direction of the electrical contact.

[0048] According to one embodiment of this aspect, the contact surface may be a flat surface adapted to form an electrical connection with a conductor cable that can be pressed against or pressed against said flat contact surface, the flat contact surface being 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 curved. The curved contact surface is suitable for forming an electrical connection with a conductor cable. The curved contact surface is particularly suitable for forming an electrical connection with a cylindrical busbar, i.e., a busbar having a disc-shaped cross section.

[0050] According to another aspect of the present invention, the object of the present invention is realized by a connection assembly including a cylindrical cross-section busbar and an electrical contact. The electrical contact may include a contact portion, a connecting portion, the connecting portion including a curved contact surface, and a transition portion, the transition portion being disposed along a longitudinal direction of the electrical contact between the curved contact surface and the contact portion. At least one first sidewall may protrude from the curved contact surface and extend along at least the transition portion relative to the longitudinal direction of the electrical contact. An electrical connection may be formed between the electrical contact and the busbar at the curved contact surface.

[0051] The invention and its advantages are explained in more detail below by means of exemplary embodiments and on the basis of the accompanying drawings, in which: [Brief explanation of the drawings]

[0052] [Figure 1] 1 is a schematic diagram of an electrical contact according to the prior art; [Figure 2] 1A and 1B are diagrams schematically illustrating an electrical contact according to a first embodiment. [Figure 3] 1 is a diagram schematically illustrating a connection assembly according to a first embodiment. [Figure 4] 10A and 10B are diagrams schematically illustrating an electrical contact according to a second embodiment. [Figure 5] 10A and 10B are diagrams schematically illustrating an electrical contact according to a third embodiment. [Figure 6] 10A and 10B are diagrams schematically illustrating an electrical contact according to a fourth embodiment. [Figure 7] 10A and 10B are diagrams schematically illustrating an electrical contact according to a fifth embodiment. [Figure 8]1 is a diagram schematically illustrating a partial cross-sectional view of a connector housing having two electrical connectors according to a first embodiment. DETAILED DESCRIPTION OF THE INVENTION

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

[0054] The contact portion 20 is insertable, particularly in the longitudinal direction 100, into a mating electrical contact (not shown). In the illustrated example, the contact portion 20 is a contact pin 26, more commonly 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 central longitudinal axis 110. The central longitudinal 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 in the longitudinal direction 100. The first end 30 is connected to the transition section 24. As shown in the example of FIG. 2, the second end 32 may be provided with a cap 28.

[0056] The contact pin 26 may include a circumferential shoulder 34. In particular, the contact pin 26 may include a single circumferential shoulder 34 along its length. The presence of the circumferential shoulder 34 forms a segment 36 between the first end 30 and the circumferential shoulder 34. The cross-section at the segment 36 is larger than the cross-section at other portions of the contact pin 26. The segment 36 of the contact pin 26 is configured to receive a seal 12 (shown in FIG. 3 ), in particular an annular seal 12. The seal 12 may have an inner diameter approximately equal to the outer diameter of the segment 36. The seal 12 may be frictionally retained 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 prior art electrical contact 1 (see FIG. 1 ). The presence of a single circumferential shoulder 34 in the contact portion 20 advantageously allows for a reduced length of the contact portion 20 while still allowing for sufficient retention of the seal 12. It is understood that the length of the contact portion is defined from the central longitudinal axis 110.

[0058] The connection part 22 is configured to form an electrical connection, in particular an electrical and mechanical connection, with an electrical conductor (shown in FIG. 3). The connection part 22 has a contact surface 38. The contact surface 38 is configured for electrical connection with the electrical conductor (shown in FIG. 3) by welding or gluing. 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 serves as a support for welding or gluing to the electrical conductor. An electrical conductor, in particular a rigid bus bar, may be arranged, preferably flat, on the flat contact surface 38.

[0059] When an ultrasonic welding process is used to form the electrical connection, the active part of the sonotrode may be moved over the busbar and emit vibrations to weld the busbar to the electrical contact 10 at the flat contact surface 38 .

[0060] Figure 3 shows a longitudinal section of the electrical contact 10 and two cross-sectional views of the electrical contact 10. Figure 3 also shows an electrical conductor 7 having an end 6 disposed on the flat contact surface 38 of the electrical contact 10. The electrical contact 10 and the electrical conductor 7 form a connection assembly. Reference is now made to Figures 2 and 3.

[0061] The connecting portion 22 has a second surface 40 opposite 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 to 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 the reference numeral 42 in Figs. 2 and 3.

[0062] The transition section 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 the first circular base 52 and the second circular base 54. The first portion 44 has a disk-like cross-section. In other words, the first portion 44 has a solid structure. The first portion 44 has a central longitudinal axis 120. The central longitudinal axis 120 of the first portion 44 is aligned with the central longitudinal 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 first portion 44 may be adapted to allow temperature measurements at peripheral wall 46 of transition portion 24, particularly for monitoring the temperature of electrical contact 100 as current flows through electrical contact 100. The thickness of first portion 44 may be adapted to make it easier to manipulate electrical contact 100 during a welding or bonding process, or when assembling electrical contact 100 into a connector housing, or both.

[0064] A second portion 50 (see FIG. 3) connects the connecting portion 22 to a first circular base 52 of the first portion 44. In the illustrated example, the first circular base 52 is perpendicular to the flat contact surface 38. In the illustrated example, the second portion has a solid structure, as shown in the cross-sectional view of FIG.

[0065] The second portion 50 includes a transition surface 48. In a first embodiment, the transition surface 48 defines a slope 56, particularly a slope of 30° to 45° relative to the flat contact surface 38. The slope 56 may have a radius 58, particularly toward the top of the slope 56 (as shown in FIG. 3). The slope 56 slopes downward in a direction from the transition portion 24 toward the flat contact surface 38. The transition surface 48 is inclined relative to the first circular base 52.

[0066] The second portion 44 protrudes relative to the first portion 50. At least one protruding surface of the second portion 44 can each function as a locking surface, for example, by forming an abutment surface against the connector housing. A locking lance of the connector housing can abut against the locking surface, which will be further described in the following paragraphs. Unintended rotation, unintended translation, or both of the electrical contact 100 can be prevented. The first circular base 52 of the first portion 44 can include a first locking surface 60. The first locking surface 60 is a flat surface. The first locking surface 60 faces the flat contact surface 38. A 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 face 40.

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

[0069] The flat contact surface 38 is disposed parallel to and offset from the central longitudinal axis 110 of the contact portion 20 and the central longitudinal axis 120 of the transition portion 24. Thus, the flat contact surface 38 is disposed eccentrically relative to the first circular base 52 of the first section 44. This offset of the flat contact surface 38 allows the central longitudinal axis 130 of the conductor to be aligned with the central longitudinal axis 110 of the contact portion 20 and the central longitudinal axis 120 of the transition portion 24 (as shown in FIG. 3 ). This arrangement allows the bulk of the electrical contact 10 to be reduced.

[0070] Unlike the prior art electrical contact 1 (see FIG. 1), the electrical contact 10 further comprises two side walls 64, 66. In the first embodiment, the side walls 64, 66 are symmetrical to each other. Therefore, hereinafter, the description of the side wall 64 also applies to the side wall 66.

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

[0072] In the connection portion 22, as shown in view (A) of FIG. 3, the sidewall 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 a direction perpendicular to the flat contact surface 38. The height 68 of the sidewall 64 may be between 1 millimeter and 50 millimeters. The height 68 of the sidewall 64 may be greater than the thickness 42 of the connection portion 22. In addition, as shown in view (A) of FIGS. 2 and 3, in the connection portion 22, the sidewall 64 has a thickness 69 defined in a 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] 3B, the sidewall 64 has a height 67. The height 67 may be substantially equal to the height 68.

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

[0075] The two side walls 64, 66 are disposed opposite each other along one side of the flat contact surface 38 in the longitudinal direction 100 of the electrical contact 10. The presence of the two side walls 64, 66 results in a "U" shaped cross section of the connection portion 22. The "U" shape refers to the shape of the letter "U" in the Latin alphabet, and the central portion of the "U" shape is flat to correspond to the flat contact surface 38.

[0076] The cross-section (A) of FIG. 3 taken across the longitudinal direction 100 shows that the cross-section of the electrical contact 10 at this point corresponds to the sum of the cross-section A1 of the end 6 of the conductor 7 and the cross-section A3 of the connection portion 22. The cross-section A3 of the connection portion 22 includes the thickness cross-section 42 and the cross-section of each of the side walls 64, 66. The cross-section A3 of the electrical contact 10 is larger than the cross-section A2 of the prior art electrical contact 1 shown in FIG. 1, which does not have side walls. The increased cross-section makes it possible to reduce the electrical resistance. The reduced resistance makes it possible to avoid overheating of the electrical contact during the passage of current.

[0077] Advantageously, the side walls 64, 66 allow for an increased cross-section of the electrical contact 10 at the transition 24, and in particular at the second portion 50 of the transition 24. Cross-section (B) of Figure 3 shows the second portion 50, beyond which the end 6 of the conductor 7 does not extend. At this point (see cross-section (B) of Figure 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 24.

[0078] The cross section A4 of the electrical contact 10 is larger than the cross section A2 of the prior art electrical contact 1 shown in FIG. 1, which does not have 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, in particular strictly larger.

[0080] In particular, the sum of the cross sections A1 and A3 is at most 2 times larger than the cross section A4, in particular at most 1.5 times larger, which prevents the cross section A4 of the electrical connector 10 at the transition section 24 from being too small compared to the cross section (A1+A3) at the connection section 22 contributed by the cross section A1 of the conductor 6.

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

[0082] 4 shows diagrammatically an electrical contact 80 according to a second embodiment. In the following, elements having the same reference numerals as those described above will not be described again, and reference is made to the description given in the preceding paragraph.

[0083] The electrical contact 80 according to the second embodiment differs 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 slope of the slope 56 of the transition surface 48 may be reduced compared to the first embodiment.

[0084] In the first embodiment, the height 68 of the side walls 64, 66 is constant along the flat contact surface 38. The electrical contact 80 according to the second embodiment differs from the first embodiment in that the height of each side wall 84, 86 from the flat contact surface 38 varies, at least partially increasing, in the direction from the connection portion 22 to the transition portion 24. In the second embodiment, ramps 88 connect the flat contact surface 38 to each corresponding free edge 70. Therefore, the volume of material required to manufacture the walls 84, 86 in the second embodiment is smaller than the volume of material required to manufacture the walls 64, 66 in the first embodiment.

[0085] In the second embodiment, each of the side walls 84, 86 may be spaced a distance 90 from a distal end 92 of the connecting portion 22 in the plane of the contact surface 38. The distal end 92 corresponds to the outermost free edge of the flat contact surface 38. 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 of the second embodiment allows for a reduction in the amount of material required to manufacture the electrical contact while ensuring sufficient transmission continuity, since the cross section A4 of the transition portion 24, i.e., the cross section at 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 view (B) of Figure 3.

[0087] 5 shows a schematic diagram of an electrical contact 90 according to a third embodiment. In the following, elements having the same reference numerals as those described above will not be described again, and reference is made to the description given in the preceding paragraph.

[0088] The electrical contact 90 according to the third embodiment differs from the first and second embodiments in that the second surface 92 opposite the flat contact surface 38 at the connecting portion 22 is a second convex surface 92. In other words, the second surface 92 is curved, and the second surface 40 is flat. Unlike 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] 6 shows a schematic diagram of 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 reference is made to the description given in the preceding paragraph.

[0090] The electrical contact 140 according to the fourth embodiment differs 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 slope of the slope 56 of the transition surface 48 may be reduced relative to the first embodiment.

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

[0092] The electrical contact 140 according to the fourth embodiment differs from the first, second, and third embodiments, respectively, 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 retention of the electrical contact 140 in the connector housing.

[0093] 7 shows a schematic diagram of 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 reference is made to the description given in the preceding paragraph.

[0094] The electrical contact 150 differs from the electrical contacts of the previous embodiments in that the transition portion 24 includes a recess 152. The recess 152 feature allows for material savings in the manufacture of the electrical contact. In particular, the volume of material in the transition portion 24 of the fifth embodiment is smaller than the volume of material in the transition portion 24 of 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. A 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 connecting portion 22 and the transition portion 24. Thus, unlike the previous embodiment, the transition surface, i.e., the bottom 154 in the fifth embodiment, is parallel to the contact surface 38. In the previous embodiment, the transition surface 48 is inclined relative to the contact surface 38.

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

[0097] Due to the presence of recess 152, transition portion 24 is provided with two side walls 158, 160, each extending along longitudinal direction 100. The outer surface of each side wall 158, 160 corresponds to a portion of outer peripheral wall 46. Transition portion 24 has a substantially U-shaped cross section at least up to wall 156. Beyond wall 156, first portion 44 of transition portion 24 has a cylindrical cross section. Side walls 158, 160, in addition to side walls 64, 66, contribute to current transmission in transition portion 24. The characteristics of recess 152 allow for material savings while ensuring sufficient current transmission in transition portion 24.

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

[0099] 7, distance 170 between sidewalls 64, 66 in connecting portion 22 is greater than distance 172 between sidewalls 158, 160, specifically by 1.2 to 1.5 times. Distance 170 is defined parallel to contact surface 38. Distance 172 is defined parallel to bottom 154 of recess 152. The recess 152 feature can simplify the form factor of electrical contact 150 by facilitating a transition between the U-shaped connecting portion 22 and the cylindrical portion of second portion 44.

[0100] Figure 8 shows a schematic cross-sectional view of a connector housing 200 including two electrical connectors 10. Figure 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 reference is made to the description given in the preceding paragraph.

[0101] The connector housing 200 may be manufactured from plastic, particularly by a plastic injection molding process. The connector housing 200 includes respective receiving portions 202 for receiving each contact pin 26 of the electrical connector 10. Each receiving portion 202 includes an opening 204 through which the contact pin 26 is inserted, particularly in the longitudinal direction 100. The openings 204 may have a circular shape. The size of the openings 204 is complementary to the diameter of the contact pin 26, particularly the diameter of the contact pin 26 between the circumferential shoulder 34 and the end portion 28. The segments 36 of the contact pin 26 may have a larger diameter than the openings 204. Thus, insertion of the contact pin 26 in the longitudinal direction 100 can be prevented by abutting the shoulder 34. Alternatively or in combination, a seal 12 arranged around the segments 36 may prevent further insertion of the contact pin 26 into the receiving portion 202.

[0102] The seal 12 provides a seal between the receiving portion 202 and the opening 204. The seal 12 is disposed between a tubular chimney 206 of the housing 200 and the segment 36 of the contact pin 26. The tubular chimney 206 extends from the opening 204 parallel to the longitudinal direction 100 and in a direction from the contact portion 20 to the connection portion 22. The tubular chimney 206 has a peripheral edge 208. The peripheral edge 208 may rest against the second circular base 54 of the transition portion 24 of the electrical contact 10. In particular, the peripheral edge 208 may rest 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 abut against the first locking surface 60 and the second locking surface 62 of each electrical contact 10, respectively. The abutment of the locking lances 214 against the locking surfaces 62, 64, respectively, can 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 receptacles 202 in the connector housing 200 is not limiting. The connector housing 200 may be adapted to receive the electrical contacts 80 according to the second embodiment. The connector housing 200 may be adapted to receive the electrical contacts 90 according to the third embodiment. The connector housing 200 may be adapted to receive the electrical contacts according to the fourth embodiment. The connector housing 200 may be adapted to receive the electrical contacts according to the fifth embodiment.

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

[0106] All the embodiments described above are not limiting but serve as examples illustrating 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. It should be noted that individual features described with respect to one embodiment may be combined with another embodiment. [Explanation of symbols]

[0107] 1. Electrical contacts according to the prior art 2 Contact part 3 Connection 4 Transition 5 Flat contact surface 6 End 7 Conductors 10 Electrical contact according to the first embodiment 12 Seals 20 Contact part 22 Connection 24 Transition 26 contact pins 28 Cap 30, 32 End of contact pin 34 Shoulder 36 contact pin segments 38 Flat contact surface 40 Second surface of the connection 42 Thickness of connection 43 Thickness of the first part 44 First part of the transition 46 Outer wall 48 Transition Surface 50 Second part of the transition 52 First circular base 54 Second circular base 56 Slope 58 Roundness 60 First Locking Surface 62 Second Locking Surface 64, 66 side wall 67 Height of side wall in first section 68 Height of side walls at connection 69 Sidewall thickness at connection 70 Free edge of side wall 80 Electrical contact according to the second embodiment 82 First Locking Surface 90 Electrical contact according to the third embodiment 92 Convex 94 Thickness in the second embodiment 100 Longitudinal 110, 120, 130 Longitudinal central axis 140 Electrical Contact According to Fourth Embodiment 142 flange 144 Flange support surface 150 Electrical Contact According to Fifth Embodiment 152 recess 154 Bottom of recess 156 Wall 158, 160 side wall 170, 172 Distance between side walls 200 Connector Housing 202 Storage Unit 204 Opening 206 Tubular Chimney 208 Periphery 210 Interface 212 Cover 214 Rock Lance A1, A2, A3, A4 cross section

Claims

1. An electrical contact (10), comprising: The electrical contact (10) 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 between the flat contact surface (38) and the contact portion (20) along the longitudinal direction (100) of the electrical contact (10); It is equipped with At least one first sidewall projects from the flat contact surface (38) and extends along at least the transition portion (24) relative to the longitudinal direction (100) of the electrical contact (10); 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); characterized in that Electrical contact (10).

2. a second sidewall, the first sidewall and the second sidewall 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); The electrical contact (10) of claim 1.

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. The electrical contact (10) of claim 1.

5. The flat contact surface (38) is arranged parallel to and offset from the longitudinal central axis (110) of the contact portion (20). The electrical contact (10) of claim 1.

6. the height of the side walls (84, 86) from the flat contact surface (38) varies so as to increase at least partially in a direction from the connection portion (22) to the transition portion (24); The electrical contact (10) of claim 1.

7. The contact portion (20) is a solid contact pin (26). The electrical contact (10) of claim 1.

8. Characterized in that it is integrally formed as a single part, The electrical contact (10) of claim 1.

9. A connection assembly comprising an electrical contact (10) according to any one of claims 1 to 8 and an electrical conductor (7), said electrical conductor (7) being welded or glued to said flat contact surface (38).

10. The conductor (7) is a conductor cable or a bus bar. The connection assembly of claim 9.

11. The conductor (7) is a conductor cable or a bus bar, The electrical conductor (7) is welded or glued only to the flat contact surface (38). The connection assembly of claim 9.

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