Contact element, plug connector having contact element and plug connector arrangement having plug connector

Abstract

The invention relates to a contact element (100), having a plug portion (200) which is shaped from a line end (210) of an electric line (220), in particular an electric stranded conductor, and has two opposite plug portion contact faces (20) which in particular point away from one another and are in particular flat, and having a contact lamella clip (300) which is fastened to the plug portion (200). The contact lamella clip (300) has a contact lamella clip rear (301) and two contact lamella clip limbs (302) which extend away from said contact lamella clip rear, wherein each of the two contact lamella clip limbs (302) has a main extension plane (302a) and a plurality of contact lamellae (303) which project from said main extension plane and are in particular resilient, wherein the contact lamellae (303) of the two contact lamella clip limbs (302) project outwards, wherein on each of the two plug portion contact faces (201) one of the two contact lamella clip limbs (302) is fastened.

Description

[0001] Description

[0002] title

[0003] Contact element, connector with contact element and connector arrangement with connector

[0004] The present invention relates to a contact element, a connector with such a contact element and a connector arrangement with such a connector.

[0005] Background of the invention

[0006] Increasingly, alternative drive components in automotive engineering are being designed with pluggable electrical connections to facilitate assembly and service. The highest demands are placed on the connectors in terms of electrical contact properties, resilience, sealing, and installation space.

[0007] WO 2005 / 096448 A1 discloses an electrical receptacle contact for high-current applications, comprising a cage-like plug receptacle for receiving a complementary plug contact, having two side parts opposite one another with respect to the plug receptacle, and comprising a contact blade insert arranged within the plug receptacle, having at least one base body extending parallel to a side part and having a plurality of contact blades, the contact areas of which protrude from the plane of the base body and are connected to the base body. The contact blades are configured as extensions connected to the base body of the contact blade insert on one side and having their contact area in the region of their free end. Disclosure of the Invention

[0008] According to the invention, a contact element, a connector with such a contact element, and a connector assembly with such a connector are proposed, each with the features of the independent patent claims. Advantageous embodiments are the subject of the dependent claims and the following description.

[0009] The invention provides a contact element that is easy to manufacture and enables reproducible positioning with low tolerance, particularly in a connector.

[0010] The contact element has a plug-in section and a contact lamella clamp which is fastened to the plug-in section.

[0011] The plug-in section is formed from a cable end of an electrical cable, in particular a stranded electrical conductor, and has two opposite, in particular mutually facing, and in particular flat, plug-in section contact surfaces. The two plug-in section contact surfaces can in particular run parallel, and the plug-in section can in particular have a cuboid shape. The electrical cable can, for example, have a round, oval cross-section or be cylindrical. The plug-in section can, for example, be formed by a compacting process, e.g. press-formed and / or with the aid of a sonotrode (introduction of ultrasound). By supplying, for example, heat and / or pressure, a previously oval or round conductor can be shaped into a square shape, wherein individual conductor strands or strands can be (cold-)welded to one another in the compacted area.The electrical cable and also the plug-in section are expediently made of a metal, in particular copper or containing copper.

[0012] The electrical cable is designed especially for high-current applications, with currents of at least 1 A or at least 10 A or at least 50 A or at least 100 A flowing through the cable and thus also through the plug-in section and the contact element. A cross-section of the electrical cable can in particular be at least 10 mm 2 or 30 mm 2 or 50 mm 2 or 75 mm 2 The cross-section of the electrical cable can be, for example, 35 mm 2 or 50 mm 2 or 95 mm 2 be.

[0013] The electrical cable is designed in particular for so-called high-voltage applications, with voltages of at least 42 V or at least 60 V or at least 100 V or at least 200 V or at least 400 V.

[0014] The contact element can be configured to be inserted into a connector housing of a connector along a plug-in direction. The plug-in direction can extend, for example, along a longitudinal axis of the contact element. It can run, for example, along the electrical line at whose end the plug-in section is formed.

[0015] The plug-in section may have a free end, in particular a distal end. This end may, for example, be a distal end, particularly when viewed along the insertion direction.

[0016] The contact blade clamp, which also represents a separate aspect of the invention, has a contact blade clamp back and two contact blade clamp legs extending therefrom, each of the two contact blade clamp legs having a main extension plane and a plurality of, in particular, resilient, contact blades protruding from this. The contact blades of both contact blade clamp legs protrude outwards. They can be contacted, for example, by a mating contact element encompassing the contact element from the outside. One of the two contact blade clamp legs is fastened to each of the two plug-in section contact surfaces. In the fastened state, the two contact blade clamp legs lie opposite each other, for example.In other words, the contact lamella clamp, when attached, has a substantially U-shape, with the two contact lamella clamp legs extending substantially perpendicularly and parallel to one another from the contact lamella clamp back, and with the contact lamellas of both contact lamella clamp legs protruding outward (pointing away from the interior of the U-shape). The contact element can advantageously be manufactured particularly easily, since the contact lamella clamp can be folded around the plug-in section like an envelope before the two contact lamella clamp legs are attached to or on the two plug-in section contact surfaces.The laborious process of aligning two individual contact lamella elements relative to each other on the two plug-in section contact surfaces prior to fastening is eliminated, as the two contact lamella clamp legs are held together by the contact lamella clamp back and are already correctly pre-positioned relative to each other. The contact lamella clamp can also be manufactured easily and cost-effectively. Incorrect orientation prior to assembly on the plug-in section can be easily avoided compared to two individual lamella elements.

[0017] For this purpose, in embodiments of the invention, the contact blade clamp can be designed, for example, as a stamped and bent part. The contact blade clamp is expediently made of a metal, in particular a copper alloy or a copper-containing alloy, e.g., brass. The contact blade clamp can be coated with a metallic layer, in particular silver or silver-containing and / or gold or gold-containing and / or tin or tin-containing.

[0018] When attached, the contact blades of both contact blade clamp legs protrude outward or point outward, facing away from each other. The "outward" direction refers to the contact element and the contact blade clamp; in contrast, for example, the contact blades of the aforementioned WO 2005 / 096448 A1 protrude inward and point toward each other.

[0019] A connector according to the invention comprises a contact element according to the invention and a connector housing which encloses the contact element. The connector housing comprises (at least) one housing guide element which interacts with (at least) one clamp guide element of the contact blade clamp in order to align the contact element in the connector housing. This advantageously enables particularly reliable and precise assembly and / or alignment and / or centering of the contact element in the connector housing using simple means.

[0020] Connector housing can be made of temperature-resistant plastic, such as polybutylene terephthalate (PBT) or polyamide (PA).

[0021] A plug connector arrangement according to the invention comprises a plug connector according to the invention and a mating plug connector with a mating contact element, wherein the mating contact element has two opposing, in particular flat, in particular facing, mating contact element surface sections, and the contact element is received between the two mating contact element surface sections.

[0022] This advantageously provides a particularly compact plug-in connection, particularly for high-current applications, in which the individual components have a high current-carrying capacity and are simple, precise and cost-effective to manufacture, and which can be plugged together easily and reliably. In particular, it is not necessary to provide an outer cage for a lamella insert, which considerably simplifies the production of the contact element. The mating contact element, in turn, can simply be formed from a workpiece, e.g. bent into a U-shape, and then contact the outward-facing lamellas from the outside. This also reduces the number of contact transition points. This is because there is only a single contact transition point from the contact lamella clamp to the plug-in section. A further transition to an outer cage or contact carrier is omitted.This advantageously reduces thermal stress, especially when transmitting high power over a longer period of time (e.g. several kW over several hours).

[0023] The mating contact element is expediently made of a metal, in particular copper or a copper alloy or a copper-containing alloy, e.g. brass. The mating contact element can be coated with a metallic layer, in particular silver or silver-containing and / or gold or gold-containing and / or tin or tin-containing. In some embodiments, the mating connector also has a mating connector housing. The mating connector housing can be made of temperature-resistant plastic, such as polybutylene terephthalate (PBT) or polyamide (PA). In one embodiment, the contact blade clamp has two contact blade clamp bent sections, wherein the contact blade clamp back is connected to one of the two contact blade clamp legs via one of the two contact blade clamp bent sections.In exemplary embodiments of the invention, the two contact blade clamp bending sections can run essentially parallel. They can, for example, laterally enclose or laterally delimit the contact blade clamp back. In particular, the contact blade clamp bending sections can serve to shape the contact blade clamp overall, and specifically the transition from the contact blade clamp back to the contact blade clamp legs, in a predetermined manner, so that the contact blade clamp can easily serve as a positioning means for the contact element, e.g., in a connector housing.

[0024] This allows the contact blade clamp to advantageously have or fulfill multiple functions integrated into a single element (e.g., providing the contact blades for reliable, tolerance-compensating contact, easy assembly on the plug-in section, simple positioning in the connector housing). This eliminates the need for the complex provision of separate elements for such functions.

[0025] In one embodiment, at least one of the two contact blade clamp bent sections has a cross-sectional profile consisting of a right-curved and a left-curved profile section. If the cross-section of the contact blade clamp is viewed so that the contact blade clamp or its U-shape opens downwards and the contact blade clamp back lies in a horizontal plane, then the contact blade clamp back defines the upper edge of the contact blade clamp, and the contact blade clamp legs extend downwards from the back and define the contact blade clamp on the right and left.In this view, a contact lamella clamp bent section borders the contact lamella clamp back on the right and left. The left contact lamella clamp bent section, starting from the contact lamella clamp back, first curves to the left to form a downward arc, and then curves to the right to transition from the arc into the left contact lamella clamp leg. The right contact lamella clamp bent section, starting from the contact lamella clamp back, first curves to the right to form a downward arc, and then curves to the left to transition from the arc into the right contact lamella clamp leg. In this view, the profile of the right contact lamella clamp bent section resembles a question mark, and that of the left a vertically mirrored question mark.

[0026] This advantageously enables particularly simple assembly of the contact lamella clamp on the plug-in section. The two contact lamella bending sections can advantageously pre-tension the contact lamella clamp, for example, elastically reversibly inwards, so that the contact lamella clamp can initially be slightly bent when slipped over or placed on the plug-in section and, as soon as the desired position relative to the plug-in section is reached, it automatically presses against the plug-in section. The process of fastening the contact lamella clamp legs on or to the plug-in section contact surfaces can be carried out calmly and without additional holding means or at least with smaller-sized holding means. Furthermore, the two contact lamella bending sections can advantageously ensure that in the event of a thickness variation or width variation (e.g.This means that, due to manufacturing-related tolerances, the contact lamella clamp legs do not have to be bent open, which could lead to a bending force even after the contact lamella clamp legs have been attached to or at the contact surfaces of the plug-in section. This provides a simple way to compensate for tolerances in the plug-in section within the contact lamella clamp. Furthermore, the bent section advantageously stiffens the contact lamella clamp. This makes it easier and more reliable to mount, center, and / or align the contact lamella clamp on the plug-in section.

[0027] In one embodiment, a first distance, in particular the smallest, between outer edges of the contact blade clamp bent sections is greater than a second distance, in particular the smallest, between the two main extension planes of the contact blade clamp legs. In other words, the right and left contact blade clamp bent sections each have an outer edge whose smallest distance is greater than the smallest distance between the main extension planes of the two contact blade clamp legs in the fastened state. For example, the smallest first distance can be at least 5% greater than the smallest second distance, preferably at least 10% greater, and particularly preferably 15% greater. The aforementioned distances are measured in particular parallel to the plane of the contact blade clamp back.In particular, the smallest distance between the outer edges of the contact lamella clamp bending sections corresponds to a maximum width of the contact lamella clamp measured parallel to the plane of the contact lamella clamp back.

[0028] In this way, the contact blade clamp bending sections can advantageously ensure reliable and reproducible alignment of the contact blade clamp and thus of the contact element in a connector housing, in particular of the connector. Furthermore, thickness tolerances or width tolerances of the plug-in section can be easily compensated. This is because centering in the connector housing can be achieved, for example, by the two contact blade clamp bending sections, whose initial distance from one another can be very precisely tolerated. Furthermore, this width difference can advantageously provide coding that allows the plug-in section to be inserted into a connector housing in only one direction.

[0029] In one embodiment, one of the two contact lamella clamp legs is welded onto each of the two plug-in section contact surfaces.

[0030] This advantageously creates a connection between the contact element and the contact blade clamp that is easy to produce, secure and permanent. At the same time, this can achieve a high current-carrying capacity and reduce the risk of loose contacts or arcing. Finally, this can advantageously achieve a particularly low contact resistance between the plug-in section and the contact blade clamp legs, which advantageously minimizes heat development at the contact points, for example when transmitting high currents, e.g. in electrically powered vehicles. In one embodiment, the plug-in section is spaced from the contact blade clamp back. For example, the length of the smallest distance between the plug-in section and the contact blade clamp back can depend on a dimension of the plug-in section contact surfaces in the direction of this smallest distance.In particular, the longer the plug-in section contact surfaces are, the smaller the distance is.

[0031] By specifying a distance, a desired position of the plug-in section relative to the contact blade clamp and thus also relative to a connector housing can be achieved. Furthermore, the distance can advantageously provide tolerance compensation against a variation in the height of the plug-in section. Even if the height of the plug-in section is particularly large (e.g., at the upper tolerance limit), the intended position of the contact blades relative to a connector housing or relative to a mating contact element can be achieved. In principle, the same contact clamp element can also be used in this way for plug-in sections of different heights (e.g., for different current-carrying capacities or currents or voltages to be transmitted). This can advantageously promote the use of identical parts (for the contact clamp element), which can save costs.

[0032] In one embodiment, the (at least one) housing guide element has a groove and the (at least) one clamp guide element has the contact blade clamp back, wherein the contact blade clamp back is received in the groove.

[0033] This advantageously allows the contact element to be aligned vertically upwards in the connector housing in a simple manner and without additional positioning elements. As shown above, the cross-section of the contact blade clamp is viewed in such a way that the contact blade clamp or its U-shape opens downwards and the back of the contact blade clamp lies in a horizontal plane. The contact blade clamp element advantageously enables the implementation of a multitude of functions as a single, integrated element. This allows the contact element to be manufactured particularly easily, cost-effectively, and reliably. For example, it can be provided that the back of the contact blade clamp rests against a floor or ceiling of the groove.

[0034] In one embodiment, the (at least one) clamp guide element has the contact lamella clamp bending sections, which rest on groove side walls of the groove as a housing guide element.

[0035] This allows the contact element to be easily aligned laterally or horizontally in the connector housing without additional positioning elements. As shown above, the cross-section of the contact clamp is viewed in such a way that the contact clamp or its U-shape opens downwards and the back of the contact clamp lies in a horizontal plane. The contact clamp element advantageously enables the implementation of a variety of functions as a single, integrated element. This allows the contact element to be manufactured particularly easily, cost-effectively, and reliably.

[0036] In one embodiment, the (at least one) housing guide element has at least one connector housing contact surface, wherein the (at least one) clamp guide element has a contact blade clamp leg contact surface, in particular on the front side, of at least one of the two contact blade clamp legs, which contact blade clamp leg contact surface protrudes in particular beyond a front plug-in section end, wherein the connector housing contact surface and the contact blade clamp leg contact surface abut one another, in particular at a front end of the contact element, so that in particular a stop is formed for the contact element when plugged into the connector housing along a plug-in direction.

[0037] This advantageously ensures that, viewed along the insertion direction, the contact element can always be mounted securely and reliably in a defined position within the connector housing. The two contact surfaces of the contact blade clamp on the one hand and the connector housing on the other hand can be manufactured with close tolerances, and the contact blade clamp can be mounted to the plug-in section with close tolerances relative to the plug-in section. If the contact blade clamp contact surface, which protrudes or projects forward beyond the plug-in section (along the insertion direction), were omitted, only the front end of the plug-in section would be available for a stop along the insertion direction (in conjunction with a front inner wall of the connector housing).However, if the plug-in section is manufactured as a compacted end, this front plug-in section end can be quite rough and have a large tolerance with respect to the leading point. It may resemble a hardened, shaggy bundle of strands (looking roughly like a bale of straw). A well-defined leading point or surface cannot be achieved without further, cost-intensive processing steps (such as cutting). The contact lamella clamp contact surface now serves as a stop and thus as a positioning aid, which advantageously eliminates the need for a further processing process (smoothing step) of the compacted end.

[0038] It can be advantageous if the contact blade clamp contact surface extends beyond the undefined front end of the plug-in section. However, it is entirely conceivable for the contact blade clamp stop surface to be approximately level with the front end of the plug-in section or even recessed behind it. In such a case, for example, the connector housing contact surface can be arranged to extend past the side of the plug-in section and rest against the contact blade clamp contact surface laterally offset from the front end of the plug-in section. It can then even serve as a stop to prevent lateral displacement (e.g., tilting or pivoting).

[0039] The connector housing contact surface can, for example, face the contact element. It can, for example, be arranged on or formed on an inner wall of the connector housing.

[0040] Alternatively or additionally, it can be provided that the connector housing has a guide web at a front connector housing end which projects inwards, in particular counter to the insertion direction, and which tapers in width, in particular when viewed counter to the insertion direction, wherein at least one contact blade clamp leg, in particular viewed along the insertion direction, projects beyond the plug-in section or protrudes above it and projects beyond the guide web or protrudes above it, in particular in such a way that the guide web forms a lateral guide or a lateral stop transverse to the insertion direction for the contact element.

[0041] The guide web can thus represent a lateral stop, in particular with regard to a displacement or pivoting or tilting of the plug-in section inwards or away from an adjacent outer wall of the connector housing.

[0042] The contact lamella clamp leg can, for example, protrude beyond a front plug-in section end. Alternatively or additionally, it can also protrude beyond an upper and / or lower plug-in section end (e.g., on the side of the contact lamella clamp back arranged at the upper plug-in section end, this protruding section can be offset to the front or rear). If a pivoting movement now occurs, the guide web, with its outer walls or laterally outward-facing surfaces, forms a stop for the contact clamp inner wall. This contact clamp inner wall then rests against it and is prevented from further pivoting or shifting in the direction of the guide web.

[0043] If both contact lamella clamp legs protrude beyond a plug-in section end (e.g. a front and / or upper and / or lower plug-in section end), the guide web can be arranged or captured between the projecting sections of the two contact lamella clamp legs (in particular when viewed transversely to the insertion direction).

[0044] This means that the contact element can be aligned in the connector housing with respect to a roll angle (i.e. a pivoting out of the contact element about an axis of rotation running along the back of the contact blade clamp or parallel to the insertion direction), and it can be aligned axially (i.e. along the axis of rotation), wherein, as above, the cross-section of the contact blade clamp is viewed in such a way that the contact blade clamp or its U-shape opens downwards and the back of the contact blade clamp lies in a horizontal plane. A surface of the guide web pointing transversely to the insertion direction can interact, for example, with an inner wall of the contact blade clamp, in particular in the area of ​​the contact blade clamp that projects beyond the front end of the plug-in section. This can, for example, be a section that also has the contact blade clamp stop surface. However, it is conceivable that it is a different area orSection of the contact lamella clamp.

[0045] The optionally tapered width of the guide bar can advantageously simplify the installation of the contact element. This is because the guide bar thus has a run-up slope on at least one side, and particularly advantageously on both sides. This allows, for example, a contact element that is initially inserted slightly crooked or tilted can be caught by a section of a contact clamp leg that protrudes beyond the front end of the plug-in section coupling with the guide bar or one of its outer sides and then sliding outward along the slope (perpendicular to the insertion direction).

[0046] If both functions are realized (front stop through the interaction of at least one contact lamella clamp leg contact surface with at least one connector housing contact surface and lateral stop through the interaction of the contact lamella clamp inner wall and the guide web), a particularly high level of functional integration into or by means of the contact lamella clamp is advantageously realized.

[0047] In one embodiment, the contact blades rest against the mating contact element surface sections. This advantageously creates a secure electrical contact between the connector and the mating connector.

[0048] A further aspect of the invention relates to a method for producing a contact element according to the invention, comprising attaching a contact lamella clamp, as described above, to a plug-in section formed from a line end of an electrical line, in particular a stranded electrical conductor, and having two opposing, in particular mutually facing, in particular flat, plug-in section contact surfaces. One of the two contact lamella clamp legs is attached, in particular welded, to each of the two plug-in section contact surfaces.

[0049] In one embodiment, the end of the electrical cable is reshaped to form the plug-in section, in particular by means of a compacting process. This compacting process can, for example, comprise the following steps:

[0050] -- Inserting one end of a cable or wire, in particular having a plurality of strands, into a compacting tool which in particular has an anvil (in the lower part), two side parts and a sonotrode (in the upper part);

[0051] -- Applying ultrasonic excitation to the end of the cable or wire using the sonotrode;

[0052] -- Application of heat and / or pressure to the end of the cable or line, in particular by means of the sonotrode.

[0053] Alternatively or in addition to the sonotrode and the ultrasonic excitation, a so-called resistance compaction can also be provided, in which the heat required for the compaction process is supplied by passing an electric current through the end of the line or cable.

[0054] In one embodiment, the contact blade clamp back and the two contact blade clamp legs are formed into a U-shape in cross-section, and / or the contact blade clamp is pushed onto the plug-in section. This allows the contact element to be formed in a simple manner.

[0055] In one embodiment, each of the two contact blade clamp legs is pressed against one of the two plug-in section contact surfaces, while the contact blade clamp leg is attached to the plug-in section contact surface. This allows the contact blade clamp to be attached tightly and over a large area to the plug-in section, thus ensuring good electrical contact. This pressing action can be applied, for example, in addition to an inward-acting spring force of the contact blade clamp.

[0056] In other words, the proposed aspects of the invention result in the following advantages:

[0057] By connecting the two contact blade legs with the back of the contact blade clamp, the bends create a rigid area that serves as a guide surface and / or contact surface, as well as for centering the contact blade clamp in the connector housing. Aligning the contact blades in the connector housing is crucial for a functioning plug connection (with the mating connector), as the contact blades must rest evenly on both sides of the contact partner (the mating contact surface sections).

[0058] The invention offers advantages particularly over direct contacting of the contact blades on a compacted cable (a compacted plug-in section), since the dimensions and, in some cases, the surface quality of a compaction and thus of the plug-in section are subject to strong tolerances, i.e., they have larger or higher tolerances than, for example, a cast plug-in section or the like. Due to these larger or higher tolerances, precise centering of individual contact blade elements (which are not connected to one another by means of a contact clamp back) on the compacted area is more difficult to implement. The contact blade clamp thus enables simple, reliable, and cost-effective production of the contact element, even if the plug-in section has larger or higher tolerances.

[0059] In addition, the width of the cable or the plug-in section can vary depending on customer requirements (e.g., regarding the currents, voltages, etc.). Advantageously, the same contact lamella clamp can be used despite such different dimensions of the plug-in section. This allows the same connector housing to be used for different cable cross-sections; the tool only needs to be adjusted, for example, using a tool insert to accommodate the cable cross-section used. Overall, this significantly simplifies the production of the contact element, the connector, and the connector assembly, making it more cost-effective and implementing it as a modular concept.

[0060] Further advantages and embodiments of the invention will become apparent from the description and the accompanying drawings.

[0061] The invention is illustrated schematically in the drawing using exemplary embodiments and is described below with reference to the drawing.

[0062] Short description of the drawings

[0063] Figure 1 shows an embodiment of a contact element in a perspective view obliquely from the front.

[0064] Figure 2 shows the embodiment of the contact element from Figure 1 in a perspective view obliquely from the side.

[0065] Figure 3 shows the design of the contact element from above.

[0066] Figure 4 shows the design of the contact element from below.

[0067] Figure 5 shows the design of the contact element from the side.

[0068] Figure 6 shows an enlarged section of the contact element in a sectional view, in which in particular a bent section of a contact element clamp back is visible.

[0069] Figure 7 shows an embodiment of a connector with the contact element and a connector housing in a cut-away side view.

[0070] Figure 8 shows a section of a cross-sectional view of the connector from the front. Figure 9 shows, in view a), a section of a sectional view of a first embodiment of a connector, and in view b), a section of a sectional view of a second embodiment of a connector.

[0071] Figure 10 shows a perspective view of a connector arrangement with the connector according to Figure 6 and part of a mating connector.

[0072] Embodiment(s) of the invention

[0073] With reference to Figures 1 to 6, a preferred embodiment of a contact element 100 according to the invention is described coherently and comprehensively below. Furthermore, with reference to Figures 7 to 9, a preferred embodiment of a connector 10 according to the invention with the contact element 100 and a connector housing 20 is described coherently and comprehensively. Figure 10 shows a perspective view of a connector assembly 1 with the connector 10 and part of a mating connector.

[0074] The contact element 100 has a plug-in section 200 and a contact blade clamp 300 fastened to the plug-in section 200. The plug-in section 200 is formed from a line end 210 of an electrical line 220; this is, for example, a compaction of the line or a compacted end. The plug-in section 200 has two opposing plug-in section contact surfaces 201. The two plug-in section contact surfaces 201 are flat or planar and point outward and away from each other. Each figure shows a (Cartesian) coordinate system (with an x-direction x, a y-direction y, and a z-direction z), in which the plug-in section contact surfaces 201 lie in the yz-plane.

[0075] The electrical line 220 can, in particular, be a stranded electrical conductor that is press-formed, ultrasonically welded, or resistance-compacted. Such a forming process can be referred to as compaction. The electrical line 220 and the plug-in section 200 comprise, for example (in particular predominantly) copper, a copper alloy, or the like, or consist thereof. The contact blade clamp 300 can, for example, also comprise copper or a copper alloy, or consist thereof. In other cases, the electrical line 200 can comprise aluminum (in particular predominantly), an aluminum alloy, or the like.

[0076] The contact lamella clamp 300 has a contact lamella clamp back 301 and two contact lamella clamp legs 302 extending therefrom or projecting therefrom.

[0077] The contact element 100 can be configured to be inserted into a connector housing 20 (see, for example, Figs. 7 to 10) of a connector 10 along an insertion direction E (which, for example, runs opposite to the y-direction y here). The insertion direction E can extend, for example, along a longitudinal axis of the contact element 100. It can run, for example, along the electrical line 220, at the end of which the plug-in section 200 is formed.

[0078] The plug-in section 200 can have a free end. This end can be, for example, a distal end, viewed along the insertion direction E.

[0079] This may be a front plug-in section end 27. The free end of the plug-in section 200 may be rough, shaggy, or heavily corrected, or may not have a smooth surface, e.g., as a result of a compacting process. For example, individual strands that were pressed together, cold-welded, or reshaped during this process may still protrude individually from the front plug-in section end 27. This is indicated, for example, in Figs. 1, 2, and 10.

[0080] The front plug-in section end 27 is located in the region of a front contact element end 24. In a rear contact element end 25, the plug-in section 200, in particular as a compacted end of the line 220, merges, for example, into the (non-compacted) electrical line 220. Each of the two contact-lamella clamp legs 302 has a main extension plane 302a and a plurality of, in particular resilient, contact lamellae 303 protruding from this plane. As can be seen from the figures, the contact lamellae 303 of both contact-lamella clamp legs 302 protrude outward and point away from each other.

[0081] The two contact lamella clamp legs 302 each have a contact lamella clamp inner wall 28 which faces the plug-in section 200.

[0082] In the figures, the main extension planes 302a also lie in the yz-plane, and the contact blades 303 protrude in the x-direction or opposite to the x-direction. The contact blade clamp back 301 lies in the xy-plane, for example.

[0083] On each of the two plug-in section contact surfaces 201, one of the two contact lamella clamp legs 302 is fastened, in particular welded, to the contact lamella clamp inner wall 28, whereby a low electrical contact resistance can be achieved.

[0084] Furthermore, the contact lamella clamp 300 has two contact lamella clamp bending sections 304, wherein the contact lamella clamp back 301 is connected to one of the two contact lamella clamp legs 302 via one of the two contact lamella clamp bending sections 304. In particular, the two contact lamella clamp bending sections 304 run essentially parallel in the y-direction and laterally enclose the contact lamella clamp back 301, i.e., they delimit the contact lamella clamp back 301 in the x-direction.

[0085] As is clearly evident from Fig. 6, for example, which shows an enlarged cross-sectional view of the right contact blade clamp bent section 304, this section has a right-curved profile section 304a and an adjoining left-curved profile section 304b. This results in an overall profile roughly shaped like a question mark. The left contact blade clamp bent section 304 is mirror-inverted.

[0086] An outermost outer edge of the contact blade clamp bending section 304 is designated by 304c, wherein a, in particular smallest, first distance between the two outer edges 304c (left and right) D1 is greater than a, in particular smallest, second distance D2 of the two main extension planes 302a of the contact blade clamp legs 302 in the x-direction (cf. Figs. 2, 3, 8, 9a, 9b).

[0087] As can be seen in particular from Figure 8 or views a) and b) of Figure 9, each of which shows a section of a cross-sectional view of the plug connector 10 according to an embodiment of the invention, one of the two contact blade clamp legs 302 is fastened to each of the two plug-in section contact surfaces 201, so that in the fastened state, the two contact blade clamp legs 302 lie opposite each other. In other words, in the fastened state, the contact blade clamp 300 has, in particular, a substantially U-shape, wherein the two contact blade clamp legs 302 extend substantially perpendicularly and parallel to each other from the contact blade clamp back 301, downwards or in the z-direction in Figures 8, 9a and 9b.

[0088] Furthermore, it can be seen that the contact blade clamp back 301 can be spaced from the plug-in section 200 (here: parallel to the z-direction z), in Fig. 9a by a first back distance d1, wherein the plug-in section 200 has a first height X1 parallel to the z-direction, and in Fig. 9b by a second back distance d2, wherein the plug-in section 200 has a second height X2 parallel to the z-direction. In both cases, the plug-in section 200 has a width in the x-direction of the second distance D2, which at the same time is only slightly smaller than the second distance between the main extension planes 302a of the contact blade clamp legs 302 (essentially determined by the (twice) material thickness of the contact blade clamp 300).

[0089] Furthermore, Figs. 8, 9a, 9b show a section of a connector housing 20 of an embodiment of a connector 10 according to the invention. The connector housing 20 has a groove 21 with a groove bottom 21a, against which the contact blade clamp back 301 rests, and groove side walls 21b, against which the contact blade clamp bent sections 304 rest. In this sense, the groove 21 represents a housing guide element that interacts with the contact blade clamp back 301 as a clamp guide element. Thus, the contact element 100 can be aligned vertically upwards (in the z-direction) and horizontally (in the -x- and x-directions) in the connector housing 20. The directions "top" and "bottom" refer to an orientation as shown, in which the contact lamella clamp back 301 lies horizontally in the xy plane and the contact lamella clamp legs protrude in the -z direction (i.e. downwards).

[0090] The groove bottom 21a forms a housing guide element that interacts with the contact blade clamp back 301 as a clamp guide element. This allows the contact element 100 to be aligned vertically upwards in the connector housing 20. Likewise, the groove side walls 21b form housing guide elements that interact with the contact blade clamp bending sections 304 as clamp guide elements. This allows the contact element 100 to be aligned laterally or horizontally in the connector housing 20.

[0091] As can be seen from Figure 7, for example, the housing guide element or the housing guide elements further comprise a connector housing contact surface 22 (here, for example, at the front inner end of the connector housing 20 shown on the left in Figure 7, facing the contact element 100). Furthermore, the clamp guide element or the clamp guide elements comprise or have a contact blade clamp leg contact surface 305 (at the outer distal end of the contact blade clamp 300 shown on the left in Figure 7).of the two contact lamella clamp legs 302, which here only protrudes by way of example beyond the front plug-in section end 27, wherein the connector housing contact surface 22 and the contact lamella clamp leg contact surface 305 abut one another (they are located abutting when viewed along the insertion direction E), in particular at a front end 24 of the contact element 100, so that in particular a stop for the contact element 100 is formed when plugged into the connector housing 20 along an insertion direction E or this stop is formed in the plugged-in state.

[0092] Figure 7 further shows that a guide web 23 is arranged at the front end of the connector housing 20, in particular on the inner side of the connector housing 20 facing the contact element 100. The guide web 23 protrudes here, for example, slightly from the connector housing contact surface 22 in the direction of the contact element 100 (in the y-direction y or opposite to the insertion direction E) or it protrudes inwards opposite to the insertion direction or backwards. In the x-direction x, which runs perpendicular to the y-direction y, the front inner end of the connector housing 20 protrudes slightly beyond the guide web 23. Here, for example, it forms the connector housing contact surface 22 on both sides of the guide web 23. A type of T-shape is formed.

[0093] At least one contact lamella clamp leg 302 (here: both contact lamella clamp legs 302) projects, viewed here only as an example along the insertion direction E, beyond the plug-in section 200 and projects beyond the guide web 23, in particular in such a way that the guide web 23 forms a lateral stop transverse to the insertion direction E for the contact element 100.

[0094] In other words: The contact lamella clamp leg contact surface 305 overlaps the guide web 23 along the insertion direction E or projects beyond it.

[0095] In this way, guidance in the x-direction x of the contact element 100 is achieved by means of the guide web 23. The guide web 23 is located, viewed in the x-direction x, between the two contact lamella clamp leg contact surfaces 305 or between the mutually facing, radially inwardly directed (parallel to the x-direction x) contact lamella clamp inner walls 28 of the two contact lamella clamp legs 302.

[0096] For example, it can be provided that the outwardly directed side surfaces of the guide web 23 extend at an angle (e.g., a width of the guide web 23 tapers opposite to the insertion direction E). In this way, they form a run-on slope for the front end of the contact blade clamp legs 302. This ensures particularly simple, secure, and reliable installation of the contact element 100 in the connector housing 20. Due to the run-on slope, a contact element 100 that may initially be slightly tilted or pivoted when inserted is automatically pivoted into the correct position about the rotation axis described above.

[0097] Figure 10 shows a section of an embodiment of a connector assembly 1 according to the invention, which has the connector 10 comprising the contact element 100 and a mating connector with a mating contact element 2 (only parts of the mating connector are shown here). The mating contact element 2, in turn, has two opposing mating contact element surface sections 2a, which in the example shown are particularly flat or planar and face one another (inwardly). To close the connector assembly 1, the contact element 100 is received between the two mating contact element surface sections 2a, with the contact blades 303 of the contact element 100 abutting the (inwardly facing) mating contact surface sections 2a.

[0098] To produce a contact element 100, as described here, for example, the contact blade clamp 300, which can be designed as a stamped and bent part and / or, for example, comprises a highly conductive material, e.g., copper, a copper alloy or the like or another metal, is first bent into a U-shape, but the transition from the contact blade clamp back 301 to the contact blade clamp legs 302 is formed with the contact blade clamp bent sections 304, as described above.

[0099] Such a contact blade clamp 300 is then placed or pushed onto a plug-in section 200, which is formed from a line end 210 of an electrical line 220, in particular an electrical stranded conductor (compacted, formed as a compacted end) and has two opposite, in particular facing away from each other, in particular flat or planar plug-in section contact surfaces 201. Such pushing-on can take place, for example, parallel to the z-direction, to the y-direction, or a combination thereof. The plug-in section 200 can, for example only, consist of copper or another metal or a material with high electrical conductivity, e.g., a superconductor, or can comprise such a metal, in particular predominantly.

[0100] Furthermore, the contact blade clamp legs 302 are pressed against the plug-in section contact surfaces 201 (whereby this can be achieved by an intrinsic spring force of the contact blade clamp 300 or such an intrinsic, inwardly directed spring force supports the pressing) and fastened thereto. For this purpose, the method can comprise pressing one of the two contact blade clamp legs 302 against each of the two plug-in section contact surfaces 201, in particular to establish a flat and flush contact, and simultaneously fastening the contact blade clamp legs 302 to the plug-in section contact surfaces 201, in particular by welding.

[0101] For this purpose, one of the two contact lamella clamp legs 302 is fastened, in particular welded, to each of the two plug-in section contact surfaces 201.

[0102] Furthermore, the method may also include reshaping the line end 210 of the electrical line 220 to form the plug-in portion 200, as already described above.

[0103] The forming may in particular comprise steps of a compacting process, such as introducing the line end 210 of the line 220, in particular with a plurality of strands, into a compacting tool which in particular has an anvil (in the lower part), two side parts and a sonotrode (in the upper part), applying an ultrasonic excitation to the line end 210 by means of the sonotrode, and supplying heat and / or pressure to the line end 210, in particular by means of the sonotrode.

[0104] Alternatively or in addition to the sonotrode and the ultrasonic excitation, a so-called resistance compaction can also be provided, in which the heat required for the compaction process is supplied by passing an electric current through the line end 210.

Claims

Claims 1. Contact element (100), comprising -- a plug-in section (200) which is formed from a line end (210) of an electrical line (220), in particular an electrical stranded conductor, and has two opposite, in particular mutually facing, in particular flat, plug-in section contact surfaces (201), and -- a contact lamella clip (300) which is fastened to the plug-in section (200), wherein the contact lamella clip (300) has a contact lamella clip back (301) and two contact lamella clip legs (302) extending therefrom, wherein each of the two contact lamella clip legs (302) has a main extension plane (302a) and a plurality of, in particular resilient, contact lamellas (303) protruding therefrom, wherein the contact lamellas (303) of both contact lamella clip legs (302) protrude outwards, wherein one of the two contact lamella clip legs (302) is fastened to each of the two plug-in section contact surfaces (201).

2. Contact element (100) according to claim 1, wherein the contact lamella clamp (300) has two contact lamella clamp bending sections (304), wherein the contact lamella clamp back (301) is connected via one of the two contact lamella clamp bending sections (304) to one of the two contact lamella clamp legs (302), wherein in particular the two contact lamella clamp bending sections (304) run essentially parallel and laterally border the contact lamella clamp back (301).

3. Contact element (100) according to claim 2, wherein at least one of the two contact blade clamp bending sections (304) has a profile in cross-section consisting of a right-curved and a left-curved profile section (304a, 304b).

4. Contact element (100) according to claim 2 or 3, wherein a, in particular smallest, first distance (D1) between outer edges (304c) of the contact blade clamp bent sections (304) is greater than a, in particular smallest, second distance (D2) between the two main extension planes (302a) of the contact blade clamp legs (302).

5. Contact element (100) according to one of the preceding claims, wherein one of the two contact lamella clamp legs (302) is welded onto each of the two plug-in section contact surfaces (201).

6. Contact element (100) according to one of the preceding claims, wherein the plug-in section (200) is spaced from the contact blade clamp back (301).

7. Connector (10) comprising -- a contact element (100) according to one of the preceding claims, -- a connector housing (20) which encloses the contact element (100) and has a housing guide element which interacts with a clamp guide element of the contact blade clamp (300) in order to align the contact element (100) in the connector housing (20).

8. Connector (10) according to claim 7, wherein the housing guide element has a groove (21) and the clamp guide element has the contact blade clamp back (301), wherein the contact blade clamp back (301) is received in the groove (21).

9. Connector (10) according to claim 7 or 8 with reference to at least claim 3, wherein the clamp guide element Contact lamella clamp bending sections (304) and the housing guide element has groove side walls (21b) of the groove (21), wherein the contact lamella clamp bending sections (304) bear against the groove side walls (21b) of the groove (21).

10. Connector (10) according to one of claims 7 to 9, wherein the housing guide element has a connector housing contact surface (22), wherein the clamp guide element has a contact blade clamp leg contact surface (305), in particular on the front side, of one of the two contact blade clamp legs (302), which contact blade clamp leg contact surface protrudes in particular beyond a front plug-in section end (27), wherein the connector housing contact surface (22) and the contact blade clamp leg contact surface (305) abut one another, in particular at a front end (24) of the contact element (100), so that in particular a stop for the contact element (100) is formed when plugged into the connector housing (20) along a plug-in direction (E), and / or wherein the connector housing (20) has a guide web (23) projecting inwards, in particular counter to the plug-in direction (E), at a front connector housing end (26),which tapers in width, particularly when viewed opposite to the insertion direction (E), wherein at least one contact lamella clamp leg (302), particularly when viewed along the insertion direction (E), projects beyond the plug-in section (200) and projects beyond the guide web (23), particularly in such a way that the guide web (23) forms a lateral stop transverse to the insertion direction (E) for the contact element (100).

11. Connector arrangement (1) comprising -- a plug connector (10) according to one of claims 7 to 10, -- a mating plug connector with a mating contact element (2), wherein the mating contact element (2) has two opposing, in particular flat, in particular facing, mating contact element surface sections (2a), wherein the contact element (100) between the two Counter contact element surface sections (2a).

12. Connector arrangement (1) according to claim 11, wherein the contact blades (303) bear against the mating contact element surface sections (2a).

13. Contact lamella clamp (300), comprising a contact lamella clamp back (301) and two contact lamella clamp legs (302) extending therefrom, wherein each of the two contact lamella clamp legs (302) has a main extension plane (302a) and a plurality of, in particular resilient, contact lamellas (303) protruding therefrom, wherein the contact lamellas (303) of both contact lamella clamp legs (302) protrude outwards when the contact lamella clamp back (301) and the two contact lamella clamp legs (302) are brought into a U-shape in cross-section.

14. A method for producing a contact element (100) according to any one of claims 1 to 7, comprising; Fastening a contact lamella clamp (300) according to claim 13 to a plug-in section (200) which is formed from a line end (210) of an electrical line (220), in particular an electrical stranded conductor, and has two opposite, in particular mutually facing, in particular flat, plug-in section contact surfaces (201), wherein one of the two contact lamella clamp legs (302) is fastened, in particular welded, to each of the two plug-in section contact surfaces (201).

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