Plug element for insertion into a printed circuit board

Abstract

The present invention relates to a plug element for insertion into a printed circuit board, comprising at least two contact sheets. Each contact sheet has at least two mutually spaced press-fit terminals extending in the same direction. The contact sheets are mutually spaced, so that a cavity is formed between two adjacent contact sheets each. The cavity or the cavities is / are at least in part filled with a material, the material located in the cavity / the cavities differing from the material of the contact sheets.

Description

[0001] Plug-in element for insertion into a circuit board

[0002] The present invention relates to a plug-in element for plugging or pressing into a printed circuit board, comprising at least two contact plates, wherein each contact plate has at least two press-in pins arranged at a distance from one another and extending in the same direction, and wherein the contact plates are arranged at a distance from one another, so that a hollow space is formed between each two adjacent contact plates.

[0003] Modern electric vehicles are powered by electric motors supplied with electrical energy by a high-voltage system. In such a high-voltage system, a high-voltage storage unit is typically used as the electrical energy source. This storage unit is connected to a high-voltage power supply, the associated power electronics, and the electric drive via appropriate high-voltage busbars. In contrast to low-voltage systems, which are primarily used in the on-board electrical system of the automotive sector, a high-voltage system uses direct voltages of over 60 V up to 1.5 kV. Alternating voltages of over 30 V up to 1 kV are also referred to as high-voltage systems.

[0004] To connect a high-voltage storage unit with the high-voltage components of the power electronics and the electric drive, as well as with the components of the charging device, standard electrical cables and corresponding connectors are used in high-voltage systems. Various plug-in elements are known for transmitting the high currents to printed circuit boards. Firstly, there are plug-in elements milled from solid material with press-in pins arranged in a grid. These connectors are often made of lead-containing materials. The disadvantage of these plug-in elements milled from solid material is the high manufacturing costs. In addition, assembly with the printed circuit board is complex. When pressing the plug-in elements into the printed circuit board, the printed circuit board must be supported by specially manufactured templates. The high press-in forces can easily cause damage to the printed circuit board. Plug-in elements designed as bent sheet metal parts are also known.In this case, a blank is punched from sheet metal and bent into the desired shape. The disadvantage is that the press-in pins in these plug-in elements can only be formed around the circumference, so the number of press-in pins per plug-in element is limited. This limits the amount of current that can be transmitted.

[0005] DE 202020 000697 U1 discloses a multi-part contact device for high-current contacting of printed circuit boards, comprising a contact basket, at least two spring elements arranged one above the other within the contact basket, and a connecting device. DE 10 2008 050 668 A1 discloses a connection element for attaching supply lines to a printed circuit board. The connection element contains a contact element produced from a piece of sheet metal by punching and bending. The piece of sheet metal is first bent into the shape of a box or cage with an approximately cube shape, with projections on the edges of the four walls that are bent so that their underside lies in one plane. A pin is formed at each of the four corners, which projects beyond the contact plane and engages into a hole in the printed circuit board during assembly. The hole can be plated through.

[0006] Further plug-in elements are known from DE 10 2004 060 084 A1. On the one hand, a plug-in element with a body made of solid material and with press-in contacts connected in one piece to a sheet metal body is shown. The sheet metal body with the press-in contacts connected in one piece is inserted into a groove in the body made of solid material. The disadvantage here is that the body is a turned and milled part. On the other hand, a plug-in element is shown that comprises a plurality of sheet metal layers on which press-in contacts are formed. Intermediate layers without press-in contacts are arranged between adjacent sheet metal layers. The sheet metal layers and the intermediate layers can be formed in one piece as a punched strip that is folded into the desired shape. It is also described that the sheet metal layers with the press-in contacts and the intermediate layers without press-in contacts are formed as individual parts and are stacked into the desired shape.

[0007] The object of the present invention is to further improve the plug-in elements known from the prior art for insertion into a printed circuit board. In particular, a plug-in element is to be provided that is inexpensive to manufacture, easy to install without damaging the printed circuit board, and capable of transmitting currents. Furthermore, the plug-in element is to be suitable for use in the automotive industry.

[0008] The object underlying the invention is achieved for a generic plug-in element for insertion into a printed circuit board in that the cavity / cavities are at least partially filled with a material and the material arranged in the cavity / cavities differs from the material of the contact plates. A cavity according to the present invention can, in its simplest form, be a space enclosed on two sides, i.e. a space delimited by two side walls. For example, the cavity can be the gap formed between two contact plates, which is delimited on two sides by a contact plate each. Filled with material in this context means that the material extends from one contact plate to the adjacent contact plate and rests against both contact plates. By using different material combinations in the plug-in element, i.e.For the contact plates and the material arranged in the cavities, it is possible to impart different properties to the contact plates and the material arranged in the cavities. This increases the functionality and, in addition, reduces the cost of the plug-in element. The press-in pins are preferably formed on only one side of the respective contact plate.

[0009] In an advantageous embodiment, it can be provided that the material arranged in the cavity(s) is designed as a spacer. The spacers are preferably made of a metallic material and extend, at least in some areas, across the entire width of the cavity formed between the contact plates. The spacers therefore bear at least partially against both contact plates, each of which borders the cavity on one side. It can also be provided that the spacers fill the entire cavity and bear against both contact plates over their entire surface.

[0010] Advantageously, the spacers can be made of a material that exhibits good electrical conductivity and / or good thermal conductivity. In this context, good electrical conductivity means that the electrical conductivity of the material used for the spacers is better than the electrical conductivity of the material used for the contact plates. The difference can also be gradual, meaning that the properties of the materials used can differ only slightly. The same applies to thermal conductivity. For example, the spacers can be made of pure copper, which has a beneficial effect on power transmission and costs.

[0011] In a further advantageous variant, at least one sensor, in particular a temperature sensor, can be arranged in the cavity(s). In particular, the sensor or temperature sensor can be embedded in the material arranged in the cavity(s). The sensor serves for data transfer and can continuously transmit measured values ​​from the contact. If the sensor is designed as a temperature sensor, measured values ​​for the temperature in the contact are determined and transmitted. It is also possible to use a sensor to measure the current in the contact.

[0012] Furthermore, it can be provided that the contact plates are made of a material that has good spring properties. Good spring properties in this context mean that the spring properties of the material used for the contact plates are better than the spring properties of the material used for the spacer(s). The difference can also be gradual, i.e. the properties of the materials used can only differ slightly. When using a material with good spring properties, the press-in pins can be designed to be springy, thus enabling simple assembly into the circuit board. In particular, spring-loaded press-in pins are essential in the automotive industry. The plug-in element according to the invention is therefore suitable for use in the automotive industry. Furthermore, these permanently elastic press-in zones orPress-in pins remain flexible throughout their entire service life, ensuring a permanently good electrical connection. Depending on requirements, a bronze alloy such as CuSn6 or a high-performance alloy such as CuNiSi or CuCrZr can be used for the contact elements or contact plates. This is not necessary for the spacers. This results in cost savings. Smart materials can also be used in the plug-in element. These smart materials increase thermal resistance and generally improve the performance of the contacts or plug-in element. An example of such a smart material for use in the plug-in element is CuAINi. Smart materials can be used for both the spacers and the contact plates. For example, the spacers can be designed as a thin plate made of a smart material, e.g. CuAINi.When the plug-in element heats up, the spacers also heat up and expand. This leads to material savings and thus a reduction in weight and cost, as well as increased thermal resistance. It is also possible to manufacture the contact plates from intelligent materials, such as CuAlNi, with the associated advantages of increased thermal resistance and the expansion and contraction of the material.

[0013] In an advantageous embodiment, the thickness of the spacers arranged in the cavities can differ from the thickness of the contact plate. This allows different grids (grid shapes, grid dimensions) to be created for the press-in pins on the circuit board. In particular, it can be provided that the thickness of the spacer(s) is greater than the thickness of the contact plates. This allows the grid of the press-in pins specified by the circuit board to be realized even when using thin contact plates. Furthermore, this embodiment can be advantageous if special connections to the contact are desired, such as press-in nuts, etc.

[0014] In a further embodiment, it can be provided that at least two of the spacers are connected to one another. This increases the stability of the plug-in element. In addition, an electrical connection of the plug-in element can be formed on the interconnected spacers. For example, at least two of the spacers can be connected to one another by means of a bracket. The electrical connection can then be formed on the bracket. In a simple embodiment, two spacers can be made from a sheet metal strip that is bent into a U-shape. This increases the stability of the plug-in element. It can also be provided that all spacers are connected to one another. The spacers can then form a busbar that forms an electrical connection of the plug-in element.

[0015] Furthermore, it can also be provided that all contact plates have the same thickness. This allows them to be manufactured from the same material, leading to cost reduction.

[0016] In yet another advantageous embodiment, all contact plates can be designed identically. The contact plates then always have the same number of press-in pins. The use of identical parts leads to further cost savings. However, it is also possible for the contact plates to have a different number of press-in pins.

[0017] A further embodiment can provide for the press-in pins to have a resilient structure. For example, the press-in pins can be designed as EON (eye of needle) contacts, so that the press-in pins have a recess that allows elastic deformation of the press-in pins in this area. This simplifies insertion of the plug-in element into the circuit board. It is also possible for the press-in pins to have at least two resilient legs. In particular, the press-in pins can then be designed as a flexible press-in zone for creating solderless electrical connections. Each press-in pin can have a needle eye with an open tip, so that two independent flexible or resilient contact legs are formed. Two sliding areas are formed, over which the legs can move independently.The press-in pin has a large cross-section and minimal embossing, which preserves the material properties. It also enables a robust design and a robust punching process. Press-in pins of this type enable uncomplicated processing, in particular protection of the circuit board and hole, i.e., long service life, low press-in forces and dispersion, low stress on the circuit board, compensation of larger hole tolerances, compensation of offset mounting, good self-centering, and even distribution of contact forces. Furthermore, a hole in the circuit board can be used multiple times, i.e., repairability is available, and high press-in speeds are possible and recommended. Further advantages of a contact formed with press-in pins of this type are that each press-in pin has four symmetrical contact points and four defined gas-tight contact zones.Only minimal deformation of the through-hole plating occurs, and high residual elasticity remains. Smaller holes enable a more compact layout. Contact resistance is very low and stable, enabling high current carrying capacity and low heat generation.

[0018] To ensure a stable structure for the plug-in element, the at least two contact plates and the spacers arranged between the contact plates can be connected to one another by means of a connecting element. In a simple embodiment, a screw, e.g., a cylinder head screw, can be used as the connecting element. This screw is arranged in a through-hole / bore in the alternating contact plates and spacers.

[0019] Advantageously, it can also be provided that the connecting element forms an electrical connection for the plug-in element. If the connecting element is designed as a cylinder head screw, a cable lug can simply be screwed on, for example.

[0020] Preferably, the at least two contact plates and the spacers can further comprise an anti-twist device. In a simple embodiment, each contact plate and each spacer has a bore for this purpose. When the plug-in element is assembled, the bores of the contact plates and the spacers lie one above the other and form a continuous channel. A locking pin is inserted or pressed into this continuous channel. This can also be understood as a transport lock, so that the package stays together during transport.

[0021] The contact can be held together either by the two connection techniques described above (screw and / or press-in pin) or by each element having a geometric feature (e.g. cup), which connects the individual plates to each other in a form-fitting manner.

[0022] Yet another advantageous embodiment can provide for at least one of the contact plates and / or at least one of the spacers to have a recess. This achieves a cooling effect.

[0023] In yet another embodiment, the plug-in element can be designed such that press-in pins are arranged on at least two sides of the contact plates. The press-in pins arranged on the respective side of the contact plate extend in the same direction. These two sides are preferably opposite sides of the contact plate. However, this is not mandatory. The plug-in element can then be used as a connecting element between different circuit board levels.

[0024] In the following, exemplary embodiments of the present invention are explained in more detail with reference to the drawings. They show:

[0025] Fig. 1 shows a perspective view of a first embodiment of the plug-in element according to the invention,

[0026] Fig. 2 shows a perspective view of a second embodiment of a plug-in element according to the invention,

[0027] Fig. 3 shows a perspective view of a third embodiment of a plug-in element according to the invention,

[0028] Fig. 4 shows the plug-in element from Fig. 3 from below,

[0029] Fig. 5 shows the plug-in element from Fig. 3 from the front,

[0030] Fig. 6 shows a perspective view of a fourth embodiment of a plug-in element according to the invention,

[0031] Fig. 7 shows a perspective view of a fifth embodiment of a plug element according to the invention,

[0032] Fig. 8 shows a perspective view of a sixth embodiment of a plug-in element according to the invention,

[0033] Fig. 9 shows a perspective view of a seventh embodiment of a plug-in element according to the invention,

[0034] Fig. 10 shows the plug-in element from Fig. 9 from the front,

[0035] Fig. 11 shows a perspective view of an eighth embodiment of a plug-in element according to the invention,

[0036] Fig. 12 shows the plug-in element from Fig. 11 from the front,

[0037] Fig. 13 shows a perspective view of a ninth embodiment of a plug-in element according to the invention, Fig. 14 shows a perspective view of a tenth embodiment of a plug-in element according to the invention,

[0038] Fig. 15 shows a perspective view of an eleventh embodiment of a plug-in element according to the invention,

[0039] Fig. 16a shows a first component of another plug-in element in perspective and from below,

[0040] Fig. 16b shows a second component of the further plug-in element in perspective and from below,

[0041] Fig. 17a shows the further plug-in element with the two components from Fig. 16a and 16b in the assembled state in a perspective view, which is plugged into a printed circuit board,

[0042] Fig. 17b shows the plug-in element from Fig. 17a inserted into a circuit board from below.

[0043] Fig. 1 shows a plug-in element 1 according to the invention, which is plugged into a printed circuit board 2. The plug-in element 1 comprises four contact plates 3, each of which is spaced apart from one another. As a result, a cavity 13 is formed between each two adjacent contact plates 3. In its simplest form, a cavity is bounded by two sides. In the present context, the cavity is the gap formed between each two contact plates 3. The cavity is therefore only bounded on two sides, each by a contact plate 3. In the exemplary embodiment shown in Fig. 1, the cavities 13 are completely filled with a material. The material arranged in the cavities 13 differs from the material of the contact plates 3. For example, a material with high thermal conductivity, such as a thermal paste, can be arranged in the cavities 13.

[0044] However, the material arranged in the cavities can also be formed as a solid body and form a spacer 6. Fig. 1 shows three spacers 6 arranged between the contact plates 3.

[0045] The contact plates 3 are identically designed. Each of the contact plates 3 has a plate-shaped region 5 whose length L and height H are significantly greater than its thickness D1. Each contact plate 3 further has four downwardly projecting press-in pins 4. All four press-in pins 4 are arranged on one side of the respective contact plate 3. In the case shown in Fig. 1, this is the underside of the respective contact plate 3. The press-in pins 4 are integrally formed on the plate-shaped region 5 of the contact plate 3. The press-in pins 4 have a springy structure. In the example shown, the press-in pins 4 are designed as EON (Eye Of Needle) contacts. Each of the press-in pins 4 therefore has a central recess 10 through which a spring effect is achieved. The press-in pins 4 are pressed into holes in the circuit board 2.The use of press-in pins to contact the circuit board enables low contact resistance, current can be transmitted at a high current, low press-in force is required, the holding force is low, and there is only slight deformation of the holes in the circuit board.

[0046] The contact plates 3 are preferably punched from a metal sheet. To enable easy insertion into a circuit board, the material of the contact plates 3 preferably has good spring properties. Depending on requirements, a bronze alloy, e.g., CuSn6, or a high-performance alloy such as CuNiSi or CuCrZr can be used as the material for the contact plates 3. In this case, good spring properties means that the material of the contact plates 3 has better spring properties than the material of the spacers 6. The differences in the spring properties can also be gradual, i.e., the properties of the materials used can differ only slightly.

[0047] The contact plates 3 are arranged at a distance from one another. A spacer 6 is arranged between each two adjacent contact plates 3. In the exemplary embodiment shown in Fig. 1, the plug-in element 1 therefore comprises three spacers 6. The spacers 6 have essentially the same shape as the plate-shaped regions 5 of the contact plates 3. Thermally conductive pads, plates made of metallic material, or even a thermally conductive paste, provided it has a sufficiently high viscosity and does not flow out of the cavity, can be used as spacers 6. Preferably, the spacers 6 are also punched from a sheet material. No press-in pins are formed on the spacers 6. The spacers 6 are formed from a different material than the contact plates 3. Since the spacers 6 do not have press-in pins, the material of the spacers does not necessarily have to have good spring properties.Preferably, a material with good electrical conductivity and / or good thermal conductivity is used for the spacers 6. Preferred materials for the spacers 6 are, for example, pure technical copper Cu-ETP, low-oxygen copper Cu-OF, aluminum (e.g., EN AW-1050), or non-metallic materials with good thermal conductivity.

[0048] In this case, good electrical conductivity or good thermal conductivity means that the material of the spacers 6 has better electrical conductivity or higher thermal conductivity than the material of the contact plates 3. The differences in electrical conductivity or thermal conductivity can also be only gradual, so that the properties of the materials used differ only slightly.

[0049] Alternatively, smart materials, e.g., CuAINi, can also be used as the material for the spacers 6 and / or the contact plates 3 in order to increase thermal resistance and enable a general improvement in performance. For example, the spacers 6 can be designed as a thin plate, e.g., made of CuAINi. In this case, the spacers 6 do not have to completely fill the cavity 13 between the contact plates 3. When the plug-in element 1 is heated, the spacers 6 made of CuAINi expand and fill the cavity 13. This leads to material savings. The thermal resistance of the plug-in element is increased. The contact plates 3 can also be made of smart materials, in particular CuAINi, with the advantages described above, such as thermal resistance and expansion and contraction of the material.

[0050] In the exemplary embodiment shown in Fig. 1, all spacers 6 are identical to one another. The thickness D1 of the contact plates 3 preferably differs from the thickness D2 of the spacers 6. In the exemplary embodiment shown in Fig. 1, the thickness D2 of the spacers 6 is greater than the thickness D1 of the contact plates 3. Because the contact plates 3 and the spacers 6 have different thicknesses, a desired pitch of the press-in pins 2 can be realized, or the pitch can be adapted to a pitch of a printed circuit board 2.

[0051] The contact plates 3 and the spacers 6 are preferably connected to one another by means of stamped stacking. The contact plates 3 and the spacers 6 thus have interacting projections and recesses that interlock in a tongue-and-groove manner, connecting the contact plates 3 and the spacers 6 to one another.

[0052] Fig. 2 shows a second embodiment of a plug-in element 1 for insertion into a printed circuit board. The plug-in element 1 according to Fig. 2 comprises five contact plates 3. Each of the contact plates 3 has a plate-shaped region 5, as already described with reference to Fig. 1, and five press-in pins 4 formed onto the plate-shaped region 5. The press-in pins 4 are designed as EON (Eye Of Needle) contacts, as in the first embodiment. In this embodiment too, all press-in pins 4 extend on one side of the respective contact plate 3. The contact plates 3 are also held spaced from one another by means of spacers 6. The plug-in element 1 according to Fig. 2 therefore comprises four spacers 6. The contact plates 3 and the spacers 6 are arranged alternately and form a plate package. As already described with reference to Fig. 1, the spacers 6 are made of a different material than the contact plates 3.

[0053] The embodiment shown in Fig. 2 differs from the embodiment shown in Fig. 1 in that the contact plates 3 and the spacers 6 have the same thickness. In the embodiment shown in Fig. 2, the thickness D1 of the contact plates 3 corresponds to the thickness D2 of the spacers 6.

[0054] Furthermore, the plug-in element 1 shown in Fig. 2 has a connecting element 7 that connects the contact plates 3 and the spacers 6 to one another. The connecting element 7 is preferably a cylinder head screw. Each of the contact plates 3 and each spacer 6 has a first recess, for example a first bore. The first recess is preferably arranged centrally in each contact plate 3 or each spacer 6. The first recesses in the contact plates 3 and in the spacers 6 are identical. In the assembled state of the plug-in element 3, the first recesses in the contact plates 3 and in the spacers 6 lie congruently one above the other, so that they form a first continuous receptacle for the connecting element 7. The connecting element 7 is arranged in this first receptacle.If the connecting element 7 is a cylinder head screw, the plug-in element 1 can have a nut into which the cylinder head screw is screwed. The nut can be pressed into the plate stack formed by the contact plates 3 and the spacers 6 or can be enclosed loosely. Alternatively, the cylinder head screw can be self-tapping and screwed into the receptacle in the plate stack.

[0055] The connecting element 7 can also form an electrical connection of the plug-in element 1. If the connecting element 7 is a cylinder head screw, a cable lug can be connected to the contact plates 3 and the spacers 6 using the cylinder head screw.

[0056] Furthermore, each contact plate 3 and each spacer 6 has a second recess 8 or second bore. The second recess 8 is arranged off-center in the corresponding contact plate 3 or spacer 6. The second recesses 8 in the contact plates 3 and in the spacers 6 are identical. The diameter of the second bores 8 is preferably smaller than the diameter of the first bores. When the plug-in element 3 is assembled, the second recesses 8 in the contact plates 3 and in the spacers 6 lie congruently one above the other, so that they form a second continuous receptacle. A dowel pin 9 is arranged, e.g. pressed into this second continuous receptacle. This creates an anti-twist device for the plate package formed from the contact plates 3 and the spacers 6.

[0057] Fig. 3 shows yet another embodiment of a plug-in element 1 according to the invention. The plug-in element 1 according to Fig. 3 comprises, as already described with reference to Fig. 2, a plate package with five contact plates 3 and four spacers 6 arranged between the contact plates 3. Each of the contact plates 3 comprises five press-in pins 4. The press-in pins 4 of the respective contact plate 3 are formed on one side of the contact plate 3. The press-in pins 4 are spaced apart and parallel to one another and extend in the same direction. The press-in pins 4 of the contact plate 3 shown in Fig. 3 have a flexible press-in zone. For this purpose, each press-in pin 4 is provided with a needle eye with an open tip, so that two independent, flexible contact legs are formed. The contact plates 3 and the spacers 6 are connected to one another by means of a connecting element 7, preferably a cylinder head screw.Furthermore, the contact plates 3 and the spacers 6 are held in place by a locking pin 9. The plug-in element 1 shown in Fig. 3 differs from the embodiment shown in Fig. 2 in that the thickness D2 of the spacers 6 is greater than the thickness D1 of the contact plates 3. This allows the desired pitch of the press-in pins 4 to be adjusted.

[0058] Fig. 4 shows the plug-in element 1 from Fig. 3 from below. Here, it can be seen that the thickness D2 of the spacers 6 is greater than the thickness D1 of the contact plates 3. The grid of the press-in pins 4 is clearly visible.

[0059] Fig. 5 shows the plug element 1 from Fig. 3 from the front. As already described, the press-in pins 4 have a flexible press-in zone. The press-in pins 4 are provided with a central recess 10 with an open tip. This creates two independent, flexible contact legs that contribute to the desired elasticity or spring action of the press-in pins 4.

[0060] Yet another embodiment of a plug-in element 1 according to the invention is shown in Fig. 6. The plug-in element 1 according to Fig. 6 is essentially designed like the embodiment shown in Fig. 1 and differs only in that the plate package formed by the contact plates 3 and the spacers 6 is held together by means of a threaded bolt 11 and a nut 12.

[0061] Another plug-in element 1 according to the invention is shown in Fig. 7. The plug-in element 1 shown in Fig. 7 comprises five contact plates 3, each arranged at a distance from one another. As a result, a cavity 13 is formed between each two adjacent contact plates 3. In its simplest form, a cavity is bounded by two sides. In the present context, the cavity is the gap formed between each two contact plates 3. The cavity is therefore only bounded on two sides, each by a contact plate 3. Spacers 6 are arranged in the four cavities 13. The spacers 6 are preferably made of a different material than the contact plates 3. The thickness of the spacers 6 is greater than the thickness of the contact plates 3. The contact plates 3 and the spacers 6 are secured with a locking pin 9.

[0062] The plug-in element shown in Fig. 7 differs from the previously described embodiments in that press-in pins 4 are formed on two opposite sides of the respective contact plate 3. The press-in pins are each formed on the top and bottom of a contact plate 3. In the embodiment shown in Fig. 7, each contact plate comprises ten press-in pins 4, five press-in pins 4 on its top side and five press-in pins 4 on its bottom side. The press-in pins are provided with a flexible press-in zone and therefore have a recess with an open tip, so that two independent flexible or resilient contact legs are formed. Of course, more or fewer press-in pins can also be provided. The plug-in element 1 according to Fig. 7 can, for example, be used to connect two circuit board levels to one another.It would also be conceivable that each contact plate is provided with press-in pins on other and / or additional sides.

[0063] Yet another plug-in element 1 according to the invention is shown in Fig. 8. This plug-in element is very similar to the plug-in element shown in Fig. 7 and comprises five contact plates 3, each arranged at a distance from one another. A spacer 6 is arranged between every two contact plates 3. The spacers 6 are preferably made of a different material than the contact plates 3. The thickness of the spacers 6 is greater than the thickness of the contact plates 3. The contact plates 3 and the spacers 6 are preferably connected to one another by means of stamping and bundling. The contact plates 3 and the spacers 6 therefore have interacting projections 17 and recesses 18, which engage in the manner of a tongue and groove connection and connect the contact plates 3 and the spacers 6 to one another. For the sake of clarity, Fig.8, the projection 17 and the recess 18 of only one of the contact plates 3 are provided with a reference numeral. The remaining contact plates 3 and spacers 6 also each have at least one projection and one recess, which engage with the recesses or projections of the adjacent contact plates or spacers. In addition, the contact plates 3 and the spacers 6 are secured with a locking pin 9. The plug-in element shown in Fig. 8 differs from the plug-in element shown in Fig. 7 in that the press-in pins 4 formed on the two opposite sides of the respective contact plate 3 are designed differently. The press-in pins 4 formed on one side, on the upper side in Fig. 8, of the contact plates 3 are provided with a flexible press-in zone and thus have a recess with an open tip, so that two independent flexible or resilient contact legs are formed.The press-in pins 4 formed on the other side, i.e., the lower side in Fig. 8, of the contact plates 3 are designed as EON (Eye of Needle) contacts. Each of the press-in pins 4 thus has a central recess 10, which creates a spring effect.

[0064] Depending on the combination of press-in contacts, the plug-in element 1 can be used to connect busbar to busbar, busbar to PCB, etc. as shown in Fig. 8. It would also be conceivable for each contact plate to be provided with press-in pins on other and / or additional sides.

[0065] As already described, the plug-in element 1 according to Figures 1 to 8 is characterized in that the contact plates 3 are made of a different material than the spacers 6. Furthermore, the thickness D2 of the spacers 6 can differ from the thickness D1 of the contact plates 3. However, it is also shown that the spacers 6 and the contact plates 3 have the same thickness. In the case where the thickness D2 of the spacers 6 differs from the thickness D1 of the contact plates 3, it would also be possible for the spacers 6 to be made of the same material as the contact plates 3.

[0066] Yet another plug-in element 1 according to the invention is shown in Fig. 9 and 10. Fig. 9 shows the plug-in element 1 in a perspective view, Fig. 10 shows the plug-in element 1 from Fig. 9 from the front. The plug-in element 1 according to Fig. 9 comprises four contact plates 3 arranged at a distance from one another. Each of the contact plates 3 comprises four press-in pins 4. The press-in pins 4 are designed as EON (Eye Of Needle) contacts, as already described with reference to other exemplary embodiments. The press-in pins 4 are formed on only one side of the respective contact plate 3. The press-in pins 4 are inserted into bores in a printed circuit board 2. A spacer 6 is arranged in each of the cavities 13 formed between the contact plates 3. A total of three spacers 6 are therefore provided. The spacers 6 in turn have a greater thickness than the contact plates 3. The two outer spacers 6 are connected to each other by means of a bracket 15.For example, the two outer spacers 6 can be formed as a single piece and have a U-shape in cross-section. The two outer spacers 6 can then be manufactured as a bent sheet metal part from a sheet metal strip. The bracket 15 is then formed as a single piece with the spacers 6. Of course, any two spacers can also be connected to one another as described. The interconnected spacers 6 can form an electrical connection 14 for the plug-in element 1. In Figs. 9 and 10, the electrical connection 14 is formed by a pin connected to the bracket 15.

[0067] Yet another plug-in element 1 according to the invention is shown in Fig. 11 and 12. Fig. 11 shows the plug-in element 1 in a perspective view, Fig. 12 shows the plug-in element 1 from Fig. 11 from the front. The plug-in element 1 according to Fig. 11 comprises four contact plates 3 arranged at a distance from one another. Each of the contact plates 3 comprises four press-in pins 4. The press-in pins 4 are designed as already described with reference to the other exemplary embodiments. In the exemplary embodiment shown in Fig. 11 and 12, the press-in pins 4 are only formed on one side of the respective contact plate 3. The press-in pins 4 are inserted into bores in a printed circuit board 2. A spacer 6 is arranged in each of the cavities 13 formed between the contact plates 3. In total, the plug-in element 1 from Fig. 11 and 12 therefore comprises three spacers 6. In the exemplary embodiment shown in Fig.11 and 12, the spacers 6 are taller than the contact plates 3 and protrude beyond the contact plates 3. The middle spacer 6 has the same thickness throughout. The two outer spacers 6 are provided with a recess to accommodate the middle contact plate 3. As a result, the spacers lie flat against one another in the area where they protrude beyond the contact plates 3. The three spacers 6 together form a busbar, which represents an electrical connection 14 of the plug-in element 1. In the upper area, i.e. in the area facing away from the contact plates 3, the two outer spacers 6 are beveled, so that the busbar formed by the spacers 6 tapers outwards.

[0068] Yet another plug-in element 1 according to the invention is shown in Fig. 13. In this exemplary embodiment, too, the contact plates 3 with the spacers 6 arranged therebetween are surrounded by a bracket 15. The contact plates 3 and the spacers 6 are preferably connected to one another by means of stamped packaging. The contact plates 3 and the spacers 6 therefore have interacting projections 17 and recesses 18 which interlock in the manner of a tongue and groove connection and connect the contact plates 3 and the spacers 6 to one another. The bracket 15 surrounds the package formed in this way with the contact plates 3 and the spacers 6 arranged therebetween on the top side and on two side walls. The bracket 15 is connected to a threaded screw 16 which forms the electrical connection 14. The bracket 15 can be manufactured in one piece or in two pieces with the threaded screw 16.Advantageously, the bracket 15 and the threaded screw 16 are manufactured as a single piece in a sintering process. Yet another plug-in element 1 according to the invention is shown in Fig. 14. The plug-in element 1 shown in Fig. 14 differs from the plug-in element shown in Fig. 13 in that the bracket 15 has a comb-like structure 19 on the inside, into which the contact plates 3 and the spacers 6 are pressed. The teeth of the chamber-like structure 19 preferably extend between the contact plates 3. In this embodiment, too, the bracket 15 surrounds the package with the contact plates 3 and the spacers 6 arranged therebetween on the top side and on two side walls. The bracket 15 is connected to a threaded screw 16, which forms the electrical connection 14. The bracket 15 can be manufactured as one piece or as two pieces with the threaded screw 16.Advantageously, the bracket 15 and the threaded screw 16 are manufactured in one piece in a sintering process.

[0069] Yet another plug-in element 1 according to the invention is shown in Fig. 15. This plug-in element 1 also comprises a bracket 15 which is connected to a threaded screw 16. As already described, the bracket 15 can be manufactured in one piece or in two parts with the threaded screw, whereby a one-piece design using a sintering process is preferred. The bracket 15 surrounds the package formed from the contact plates 3 and the spacers 6 on the top side and on all side walls. Only the underside, on which the press-in pins 4 are formed, is not surrounded by the housing. However, it is also conceivable to use a bracket 15 which forms a completely closed housing. The bracket 15 shown in Fig. 15 also has a comb-like structure on the inside, into which the contact plates 3 and the spacers 6 are pressed.

[0070] The plug-in elements 1 shown in Figures 13 to 15 also show that the contact sheets 3 and the spacers 6 are connected to one another by means of at least one caulking, for example by punching and stacking. It is advantageous to carry out the caulking in a continuous process until the desired stack height is reached. While it is also possible to first arrange the individual sheets into a stack and then press them together, damage cannot be ruled out due to the higher forces required for this. In principle, it is conceivable that the stack is connected solely by such caulking. However, additional pins can also be used to connect the contact sheets 3 and the spacers 6 to one another.

[0071] If the bracket 15 has the comb-like structure 19, assembly of the package formed from the contact sheets 3 and the spacers 6 is only possible from below and / or from below and the side. In the embodiments shown in Fig. 1 to 15, the plug-in element is essentially square, i.e. the number of contact sheets in the plug-in element corresponds to the number of press-in pins formed per contact sheet. However, it is also possible for the number of contact sheets in the plug-in element to differ from the number of press-in pins formed per contact sheet. Rectangular designs of the plug-in element are therefore also possible. The design of the plug-in element according to the invention increases the design variety, particularly in comparison with plug-in elements milled from solid material. Furthermore, it can be provided that sensors, for example temperature sensors, are arranged in the cavities between the contact sheets.The sensors can, for example, be embedded in the spacers or form the spacers.

[0072] Preferably, the plug-in elements and / or spacers are coated, e.g., silver (Ag) over nickel (Ni). The thickness of the coating is on the order of a few microns. This can reduce the contact resistance.

[0073] Figures 16a, b and 17a, b show a further plug-in element 21 which is composed of two components 22, 23. Figure 16a shows the first component 22 of the plug-in element 21 in a perspective view and from below. Figure 16b shows the second component 23 of the plug-in element 21 in a perspective view and from below. Figure 17a shows the plug-in element 21 composed of the first component 22 and the second component 23 in the plugged-in state in a printed circuit board 24 in a perspective view. Figure 17b shows the plug-in element 21 plugged into the printed circuit board 24 from below.

[0074] The first component 22 of the plug-in element 21 is a bent sheet metal part that is preferably stamped from sheet metal. The first component 22 is designed as a downwardly open first hollow body 25. On its upper side, the first hollow body 25 has a centrally arranged first circular opening 26. On both sides of the first circular opening 26, two slots 27 arranged parallel to one another are formed. The hollow body 25 further comprises four side walls that enclose a cube- or cuboid-shaped volume. At the ends of the side walls facing away from the upper side of the hollow body 25, four press-in pins 28 are formed on each of the four side walls. The press-in pins 28 extend downward as an extension of the side walls and are arranged at a distance from one another. The press-in pins 28 are therefore only formed on the circumference of the first component 22.

[0075] The second component 23 of the plug-in element 21 is also a bent sheet metal part that is preferably punched from sheet metal. The second component 23 is essentially U-shaped. This means that it comprises an upper side to which two parallel side walls are connected at right angles. As an extension of the side walls, three press-in pins 28 are formed on each side wall. The press-in pins 28 are spaced apart and arranged parallel to one another. The second component 23 of the plug-in element 21 has a smaller width than the first component 22 of the plug-in element 21. The width and thickness of the side walls of the second component 23 essentially correspond to the thickness and width of the slots 27 in the upper side of the first component 22. In the second component 23, too, the press-in pins 28 are formed only along the circumference.

[0076] During assembly of the plug-in element 21, the second component 23 is inserted into the first component 21 such that the side walls of the second component 23 extend through the slots 27 formed in the top side of the first component 21 into the interior of the first component 22. The side walls of the second component 23 are arranged at a distance from the side walls of the first component 22 such that a hollow space is formed between the side walls of the second component 23 and the side walls of the first component 22. This hollow space is filled with air. The plug-in element 21 therefore consists of two components 22, 23 inserted into one another. This is shown in Fig. 17a. The plug-in element 21 is therefore not only provided with press-in pins 28 along its circumference, but also has press-in pins 28 arranged in its surface. This increases the density of press-in pins per surface area, whereby larger currents can be transmitted.This can be seen in Fig. 17b. The press-in pins 28 are inserted into plated-through holes in the circuit board 24.

[0077] In the plug element 21 shown in Figures 16a, b and 17a, b, the press-in pins are also designed as EON (Eye of Needle) contacts, with the associated advantages. In particular, only minimal force is required to press the plug element into the circuit board, the press-in pins can be pressed out of the circuit board again, and the risk of damage to the circuit board is reduced during both pressing in and pressing out, enabling simple assembly.

[0078] As described above, both the first component 22 and the second component 23 of the plug-in element 21 are formed as bent sheet metal parts. Advantages of bent sheet metal parts include lower manufacturing costs, the ease of assembly of the components, and the avoidance of damage to the circuit board when installing the plug-in element on the circuit board.

[0079] 1 plug-in element

[0080] 2 circuit board

[0081] 3 contact plate

[0082] 4 press-in pin

[0083] 5 plate-shaped area contact sheet

[0084] 6 spacers

[0085] 7 Connecting element

[0086] 8 second recess

[0087] 9 locking pin

[0088] 10 Recess press-in pin / press-in zone

[0089] 11 threaded bolts

[0090] 12 Mother

[0091] 13 Cavity

[0092] 14 electrical connection

[0093] 15 brackets

[0094] 16 threaded screw

[0095] 17 lead

[0096] 18 Deepening

[0097] 19 comb-like structure

[0098] 21 plug-in element

[0099] 22 first component

[0100] 23 second component

[0101] 24 circuit board

[0102] 25 first hollow body

[0103] 26 first circular opening

[0104] 27 slot

[0105] 28 Press-in pin / press-in zone

Claims

Claims 1. Plug-in element (1) for plugging into a printed circuit board (2) comprising at least two contact plates (3), wherein each contact plate (3) has at least two press-in pins (4) arranged at a distance from one another and extending in the same direction, and wherein the contact plates (3) are arranged at a distance from one another such that a cavity (13) is formed between each two adjacent contact plates (3), characterized in that the cavity / cavities (13) are at least partially filled with a material and the material arranged in the cavity / cavities (13) differs from the material of the contact plates (3).

2. Plug-in element (1) according to claim 1, characterized in that the material arranged in the cavity / cavities (13) is designed as a spacer (6).

3. Plug-in element (1) according to claim 1 or 2, characterized in that the material arranged in the cavity / cavities (13) or the spacers (6) consist of a material which has good electrical conductivity and / or good thermal conductivity.

4. Plug-in element (1) according to at least one of claims 1 to 3, characterized in that at least one sensor, in particular a temperature sensor, is arranged in the cavity / cavities.

5. Plug-in element (1) according to one of claims 1 to 4, characterized in that the contact plates (3) consist of a material which has good spring properties.

6. Plug-in element (1) according to one of claims 2 to 5, characterized in that the thickness (D2) of the spacer(s) (6) differs from the thickness (D1) of the contact plates (3).

7. Plug-in element (1) according to one of claims 2 to 6, characterized in that at least two of the spacers (6) are connected to one another.

8. Plug-in element (1) according to one of claims 1 to 7, characterized in that all contact plates (3) each have the same thickness.

9. Plug-in element (1) according to one of claims 1 to 8, characterized in that the contact plates (3) are of identical design.

10. Plug-in element (1) according to one of claims 1 to 9, characterized in that the press-in pins (4) have a resilient structure.

11. Plug-in element (1) according to one of claims 2 to 10, characterized in that the at least two contact plates (3) and the spacers (6) arranged between the contact plates (3) are connected to one another by means of a connecting element (7).

12. Plug-in element (1) according to claim 11, characterized in that the connecting element (7) forms a connection of the plug-in element (1).

13. Plug-in element (1) according to one of claims 2 to 12, characterized in that the at least two contact plates (3) and the spacers (6) have an anti-twist device.

14. Plug-in element (1) according to one of claims 2 to 13, characterized in that at least one of the contact plates (3) and / or at least one of the spacers (6) has a recess.

15. Plug-in element (1) according to one of claims 1 to 14, characterized in that press-in pins (4) are formed on at least two sides of the contact plates (4).

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