Flat contact socket

Abstract

The invention relates to a flat contact socket for a rectangular flat contact plug, comprising a socket housing and a one-piece cage-shaped lamella insert for receiving and electrically contacting the flat contact plug. The cage-shaped lamella insert is received in a cuboidal cavity of the socket housing, and the lamella insert has at least one substantially circumferential edge, a flat contact opening defined by the circumferential edge for inserting the flat contact plug, and a plurality of inner lamellae, said inner lamellae being connected to the circumferential edge, protruding inwards with respect to the circumferential edge, and being provided for electrically contacting the flat contact plug. The lamella insert is resiliently supported in the cavity of the socket housing in such a way that at least the circumferential edge of the lamella insert can be moved relative to the socket housing in the thickness direction and / or the width direction. The invention further relates to a method for producing a one-piece cage-shaped lamella insert and to a method for producing a flat contact socket.

Description

[0001] Flat contact socket

[0002] The present invention relates to a flat contact socket for a rectangular flat contact plug, comprising a socket housing and a one-piece cage-shaped lamellar insert for receiving and electrically contacting the flat contact plug. The cage-shaped lamellar insert is received in a cuboid hollow form of the socket housing and is provided for electrical contact with the socket housing. The lamellar insert has at least one substantially circumferential rim, a flat contact opening defined by the circumferential rim for inserting the flat contact plug, and several inner lamellae. The inner lamellae are connected to the circumferential rim, project inwards from the circumferential rim, and are provided for electrically contacting the flat contact plug.Furthermore, the invention relates to a method for manufacturing a one-piece cage-shaped lamellar insert and a method for manufacturing a flat contact socket.

[0003] Various connection techniques are generally known for the electrical contacting of current-carrying conductors and electrical components. Besides rigid screw or weld connections, electrical contacting using plugs and sockets enables a flexible and quick connection between electrical components. Such pluggable and detachable connecting elements for contacting electrical components, as well as suitable manufacturing processes, are available in various variations and designs. In the automotive sector, rectangular flat contact plugs have been successfully used for many years to connect wiring harnesses and electrical components, with the connections to the electrical conductors predominantly implemented as crimp contacts.Rectangular flat contact connectors have an aspect ratio (width to thickness) of at least 2 and preferably greater than 5 when projected along the insertion direction. These rectangular flat contact connectors are inserted into corresponding flat contact sockets for electrical contacting of conductors and components.

[0004] Plug connectors for the electrical connection of components are also used in modern electric vehicles to supply the high-performance electric motors used for vehicle propulsion and the associated power electronics with electrical energy via a high-voltage system. In contrast to low-voltage systems, which are used in vehicle electrical systems as well as for controlling the power electronics of electric drives and for industrial drives, high-voltage systems use direct current voltages between 60 V and 1.5 kV or alternating current voltages between 30 V and 1.0 kV.

[0005] The contacting technologies and conductors used in the high-voltage system of an electric vehicle for the electrical connection of the high-voltage storage system, power electronics, and electric motors must ensure reliable current transmission at all times while simultaneously preventing excessive temperature increases at the connection points and throughout the entire high-voltage system. For this reason, especially in the automotive sector, it is essential that the electrical connections of the components are secure and vibration-resistant, as relatively high currents are typically conducted through the conductors and connection points in a high-voltage system. Accordingly, a good electrical contact with low electrical contact resistance between the contact elements is particularly important for plug connections to minimize heat generation at the connection point due to electrical contact resistance.

[0006] To reduce the overall costs of high-voltage systems for electric vehicles, manufacturers are constantly trying to widen the manufacturing tolerances for the required electrical components to enable more cost-effective production. This places an additional demand on the connectors of high-voltage systems, which must compensate for the larger manufacturing tolerances of cost-effectively produced components without compromising electrical performance.

[0007] In addition to rigid screw or welded connections of high-voltage components, which exhibit relatively low contact resistance, rectangular flat contact connectors are also known in the prior art for the electrical contacting of components in a high-voltage system. These connectors, in conjunction with a flat contact socket, enable reliable electrical contact with low contact resistance and high current-carrying capacity between the high-voltage components. For example, German patent application DE 20 2004 013 160 U1 describes a flat contact socket that has a pocket-like insertion channel in a flat housing for a rectangular flat contact connector. The connector is formed by two opposing lamellar walls attached to the socket housing.DE 10 2005 017 988 B3 describes a further flat contact socket with an electrical contact sleeve for receiving and connecting a flat contact plug, wherein the contact sleeve has a plurality of elongated spring elements that extend between an insertion opening and an end face of the contact sleeve and are pre-bent inwards. These flat contact sockets, known from the prior art, are typically provided with crimp contacts into which flexible electrical conductors are pressed. Crimped connecting leads of the flat contact sockets allow for tolerance compensation in the event of heating of such connectors or during the assembly of the plug contact.Despite strong temperature differences, confined assembly conditions, external environmental loads or misalignment of the plug elements during assembly of the connector, contact problems can still occur between the flat contact plug and the flat contact socket, increasing the contact resistance of the connector and causing the plug contact to heat up excessively due to the heat loss induced by the contact resistance.

[0008] The present invention is therefore based on the objective of providing an improved flat contact socket for a flat contact plug, which enables a simple plug connection with the flat contact plug and which permanently enables a secure current transmission between the flat contact plug and the flat contact socket.

[0009] The problem underlying the invention is solved for a generic flat contact socket by supporting the lamellar insert in the hollow form of the socket housing in such a way that at least the circumferential edge of the lamellar insert is movable relative to the socket housing in the thickness direction and / or the width direction, preferably at least in the thickness direction. Such a floating mounting, in which the cage-shaped lamellar insert is neither materially nor positively bonded to the housing, but is merely secured against falling out or being unintentionally pulled out, allows, in the case of a plug connection of a rectangular flat contact plug with the flat contact socket, a significant offset of the flat contact plug relative to the flat contact opening of the lamellar insert defined by the circumferential edge for insertion and receptacle reception of the flat contact plug.Preferably, not only the surrounding edge of the lamella insert, but the entire lamella insert itself is relatively freely movable relative to the socket housing. When the flat contact plug is inserted into the cage-shaped lamella insert, the flat contact opening defined by the surrounding edge can move in the direction of a flat contact plug positioned with an offset to the flat contact opening, in the thickness and / or width direction of the lamella insert, thus enabling trouble-free insertion and secure contact of the flat contact plug in the flat contact socket.The thickness and width directions of the lamella insert are defined by the rectangular shape of the flat contact connector in the projection of the insertion direction, wherein the rectangular flat contact connector has a thickness and a width that are at least twice its thickness, and wherein the thickness and width of the flat contact connector define a thickness direction and a width direction for the flat contact socket and the lamella insert that are oriented perpendicular to the insertion direction of the flat contact connector. This particular electrical contact between a flat contact socket according to the invention and a flat contact connector inserted into the flat contact opening defined by the circumferential edge of the cage-shaped lamella insert enables, particularly for use in a high-voltage system, a low contact resistance of the entire connector.This allows a high current carrying capacity to be achieved in accordance with the requirements of the high-voltage components supplied via this connection, and limits the heat input due to the heat loss during current transfer at the respective contact points between the flat contact socket and the flat contact plug to a temperature rise of the connector that is permissible for operation.

[0010] A preferred embodiment provides that the mobility of the spring-supported lamellar insert relative to the socket housing in the thickness direction is at least 25%, preferably at least 50%, and particularly at least 75% of the thickness of the associated flat contact connector. Such mobility of the spring-supported lamellar insert within the cuboid hollow shape of the socket housing allows a significant offset of the flat contact connector relative to the flat contact opening when the flat contact connector is inserted into the flat contact socket, thereby facilitating assembly, in particular automated assembly of a rectangular flat contact connector into a flat contact socket according to the invention.The values ​​for the mobility of the spring-supported lamella insert, starting from an unloaded position of the lamella insert in the hollow form of the socket housing, refer to both directions of the thickness direction, resulting in a total range of movement of the flat contact connector in the socket housing of at least 50%, preferably at least 100%, and particularly at least 150% of the thickness of the associated flat contact connector. The mobility of the spring-supported lamella insert in the socket housing of a flat contact socket according to the invention is particularly advantageous when using several flat contact sockets connected in series, which are intended for contacting several flat contact connectors connected in series in the thickness direction.When several conventional flat contact plugs or sockets are connected in series, the manufacturing tolerances add up, significantly increasing the requirements for permissible tolerances in the production of the plugs and sockets. Furthermore, such series connections increase assembly effort and the risk of faulty electrical contact, resulting in reduced current carrying capacity and impermissible heating of the connection. Ideally, the movement of the spring-loaded lamellar insert relative to the socket housing in the thickness direction can be a maximum of 200%, and the movement range of the flat contact plug within the socket housing can be a maximum of 400% of the thickness of the corresponding flat contact plug.

[0011] To reliably accommodate a two-dimensional misalignment of the flat contact connector relative to the flat contact opening, the movement of the spring-supported lamellar insert relative to the socket housing in the lateral direction can be at least 3%, preferably at least 5%, of the width of the associated flat contact connector. Advantageously, the movement of the spring-supported lamellar insert relative to the socket housing in the lateral direction can be a maximum of 25% of the width of the associated flat contact connector. Such lateral movement of the cage-shaped lamellar insert, achieved by its sliding mounting in the cuboid hollow of the socket housing, facilitates the manual or automated assembly of the rectangular flat contact connector in the flat contact socket according to the invention, as the lamellar insert is also movable in the lateral direction.Further tolerance compensation in the width direction can be achieved by designing the width of the lamellar insert in relation to the flat contact connector as required, if moving the flat contact connector during assembly is necessary but not for the insertion process.

[0012] A useful design provides that the lamellar insert is resiliently supported in the hollow form of the socket housing such that it can be tilted relative to the width of the socket housing in the insertion direction, preferably by at least 3°, and particularly between 5° and 10°. The width of the socket housing refers to the areas of the housing opening relative to the cuboid hollow form in the width direction. The tiltability of the lamellar insert within the hollow form facilitates its movement in the thickness direction and thus also the insertion of a flat contact connector with a large offset in the thickness direction.When inserting a flat-contact plug, which is offset from the flat-contact socket, into the flat-contact opening of the cage-shaped lamellar insert, movement of the lamellar insert can initially only occur in the area of ​​the flat-contact opening. The parts of the lamellar insert located deeper within the hollow of the socket housing only undergo a slight lateral movement, as the entire lamellar insert tilts within the hollow of the socket housing. This allows for the insertion of the offset flat-contact plug with minimal insertion force and without interrupting or negatively affecting the electrical contact between the lamellar insert and the socket housing. Advantageously, the lamellar insert can be tilted by a maximum of 25° relative to the insertion direction relative to its wider sides.

[0013] A simple solution for the resilient support of the movable lamellar insert and its electrical contact with the socket housing provides for several outwardly projecting, resiliently pre-tensioned outer lamellae connected to the edge of the lamellar insert. At least one outer lamella, preferably at least two, is provided on each side of the cage-shaped lamellar insert. The outer lamellae extend resiliently from the circumferential edge of the cage-shaped lamellar insert towards the cuboid hollow of the socket housing to ensure reliable electrical contact with the socket housing, despite the lamellar insert's movement in the thickness and / or width direction. The width of the cage-shaped lamellar insert is defined as the portion of the circumferential edge that extends in the width direction of the lamellar insert.The simultaneous arrangement of outer lamellae and inner lamellae connected to the circumferential rim enables cost-effective manufacturing of the lamella insert and the socket housing, as well as reliable electrical contact between the socket housing and the flat contact connector. Providing at least two outer lamellae per side of the width allows for uniform support. Preferably, the number of outer lamellae is one greater than the number of inner lamellae on each side of the width; for example, with two inner lamellae per side of the width, three outer lamellae are preferably present. This prevents unintentional twisting relative to the hollow shape of the socket housing when the flat contact connector is inserted into the cage-shaped lamella insert.

[0014] A particular variant provides that the spring-loaded outer lamellae are in electrical contact with an inner wall of the bushing housing at a contact point, and that the contact point of at least one outer lamella is designed as an outwardly projecting dome. Preferably, all outwardly projecting spring-loaded outer lamellae have a dome-shaped contact point for electrical contact with an inner wall of the bushing housing. This ensures not only reliable contact between the outer lamellae and an inner wall of the bushing housing, but also good contact between the outer lamellae and the hollow shape of the bushing housing, despite the movement of the spring-loaded lamella insert.Conveniently, the edge of the cage-shaped lamellar insert can be designed as a closed ring, making the edge, and consequently the entire lamellar insert, stable and resistant to warping. In a curved embodiment of the lamellar insert, the butt edges of the rim can preferably be bonded together, in particular welded. Alternatively, the butt edges of the rim can be positively connected, especially for larger flat contact connectors, whereby such a positive connection of the rim not only reduces the number of necessary work steps but is also more cost-effective.

[0015] An alternative embodiment provides that the cage-shaped lamellar insert has a front edge, which forms the circumferential rim, and a rear edge, wherein the inner lamellae preferably extend from the front edge to the rear edge and are particularly firmly connected to the front and rear edges, and wherein the outer lamellae are preferably arranged only at the front edge or the rear edge, particularly only at the front edge. Providing a front edge and a rear edge on the cage-shaped lamellar insert increases the stiffness and strength of the lamellar insert, especially when the front edge and / or the rear edge is designed as a closed ring. At the same time, this cage-shaped design of the lamellar insert improves handling during the assembly of the flat contact socket.In this design, the flat contact opening of the cage-shaped lamellar insert is defined by the front circumferential edge.

[0016] For a stable construction of the cage-shaped lamella insert, the inner lamellae can be attached to the front and rear edges, with the legs of the inner lamellae attached to the front and rear edges each bent inwards relative to the flat contact opening, preferably at an angle between 10° and 25°, and particularly between 15° and 20°, relative to the insertion direction. This ensures both good guidance of the flat contact connector when inserted into the lamella insert and good electrical contact of the flat contact connector.

[0017] In a further embodiment, the contact section of the inner lamellae can be located at the apex between the inwardly curved inner legs of the inner lamellae, in a region between 40% and 60% of the distance between the front and rear edges, and in particular approximately midway between the front and rear edges. These contact sections or apex points of the inner lamellae, arranged essentially centrally and forming corresponding internal contact points for electrical contact with the flat connector, enable both sufficient guidance when inserting the flat connector into the lamella insert and the establishment of a reliable electrical connection, as well as sufficient clearance for necessary tolerances regarding the insertion depth of the flat connector into the flat socket and tolerance compensation in the thickness direction.

[0018] For a stable design of the lamella insert, at least two inwardly projecting inner lamellae can be provided on each side of the insert. This ensures not only high torsional rigidity of the lamella insert but also reliable electrical contact with the flat connector. The two inner lamellae on each side of the insert can have different contact heights relative to the flat connector, or different distances from the front edge, in the insertion direction. This allows for improved electrical contact even if the flat connector is significantly misaligned with the center of the cuboid hollow of the socket housing, i.e., after movement of the lamella insert in the thickness and / or width direction during insertion.

[0019] A practical design for the flat contact socket provides for at least two outwardly projecting, spring-loaded outer lamellae on each side of the lamella insert. These at least two outer lamellae are preferably attached to a front edge and are in electrical contact with an inner wall of the socket housing within the hollow section. This allows for good support of the cage-shaped lamella insert within the hollow section of the socket housing while simultaneously permitting its movement relative to the socket housing in the thickness and / or width direction.

[0020] In a particular embodiment, the at least two outer lamellae on each side of the width can have a different contact height relative to the socket housing in the insertion direction of the flat contact plug, wherein the different contact heights of the at least two outer lamellae on each side of the width are preferably arranged above and below a contact height of the associated inner lamellae with a flat contact plug, i.e. the vertices or the contact sections of the inner lamellae.This special arrangement of the contact points of the inner and outer lamellae relative to the flat contact connector, as well as the hollow shape of the socket housing, ensures good and secure support of the flat contact connector in the cage-shaped lamella insert and the lamella insert in the hollow socket housing, even when the insertion position of the flat contact connector is offset in the thickness and / or width direction, and when the lamella insert is tilted within the cuboid hollow shape. This also results in a sufficiently high normal contact force. Thus, the varying contact height of the outer lamellae ensures improved electrical contact and high current-carrying capacity.

[0021] An effective design for different contact heights provides that the at least two outer lamellae on each side of the width are bent outwards differently, wherein on each side of the width, a spring leg of a first outer lamella, attached to the front edge, preferably has a smaller bending angle than a spring leg of a second outer lamella, also attached to the front edge. In this embodiment, the bending angle refers to the insertion direction of the flat contact connector and the front edge of the lamella insert.

[0022] In a suitable embodiment, the spring leg of the first outer lamella can be bent outwards in a range between 10° and 30°, preferably between 15° and 25°, relative to the insertion direction, and a free end of the first outer lamella, which adjoins the spring leg at a contact point of the first outer lamella with the inner wall of the bushing housing, can be bent inwards relative to the spring leg of the first outer lamella, particularly in a range between 10° and 30°, preferably between 15° and 25°. This design of the first outer lamella with a bent spring leg and a free end enables good guidance of the cage-shaped lamella insert during its installation in the hollow form of the bushing housing and simultaneously also ensures reliable electrical contact with the bushing housing regardless of the offset and inclination of the lamella insert relative to the hollow form.The contact point of the outer lamella for electrical contact with the socket housing also defines the respective contact height to the outer lamella. In an advantageous embodiment of the differently curved outer lamellae, the spring leg of the second outer lamella can be bent outwards in a range between 30° and 50°, preferably between 35° and 45°, relative to the insertion direction, and a free end of the second outer lamella, which adjoins the spring leg at a contact point of the second outer lamella with the inner wall of the socket housing, can be bent inwards relative to the spring leg of the second outer lamella, particularly in a range between 5° and 25°, preferably between 10° and 20°.

[0023] One embodiment of a flat contact socket according to the invention provides that outwardly angled insertion tabs projecting in the opposite direction of insertion are provided at the front edge of the cage-shaped lamellar insert, preferably at least two insertion tabs are provided on each side of the lamellar insert, and wherein the insertion tabs are angled outwards towards the socket housing, particularly within an angle range of 10° to 45°, preferably between 20° and 30°. Such outwardly angled, projecting insertion tabs enable, in the event of an offset of a flat contact plug relative to the flat contact opening, particularly in the thickness direction, secure and uniform guidance of the flat contact plug and the resulting movement of the lamellar insert to compensate for any offset of the flat contact plug.The insertion tabs reliably prevent the flat contact plug from tilting and becoming blocked relative to the lamellar insert when it is plugged in.

[0024] A practical design provides for at least one stop tab on each of the front edges of the lamellar insert. These stop tabs are bent outwards from the front edge of the lamellar insert, preferably at an angle between 80° and 100°, and ideally around 90°, relative to the insertion direction. The stop tabs ensure secure positioning of the lamellar insert in the insertion direction. When inserting the flat contact connector into the cage-shaped lamellar insert, the insertion force is transferred directly to the socket housing via the stop tabs, which bear against the socket housing. During assembly of the flat contact socket, the stop tabs on the edge of the lamellar insert prevent the insert from being inserted too far into the hollow of the socket housing.

[0025] One modification provides that a lateral receptacle for the stop tabs is provided on each of the thickness-directed sides of a housing opening in the cuboid hollow form of the socket housing, preferably a recess in the socket housing on the thickness-directed sides of the housing opening, and wherein, in particular, the length of the lateral receptacles, preferably the recesses, is greater in the thickness direction than the width of the stop tabs in the thickness direction, particularly by a factor of 1.2 to 2.5, preferably by a factor of 1.3 to 1.9. Such enlarged lateral receptacles for the stop tabs limit the movement of the cage-shaped lamellar insert in the thickness direction during the insertion process, as well as the maximum inclination of the lamellar insert, and enable a low-incline positioning of the lamellar insert in the event of misalignment of the flat contact connector.In this case, a recess in the side edges of the bushing housing is a simple solution for shaping the lateral recesses of the stop tabs, whereby for a balanced dimensioning of the lateral recesses, their size is designed according to the desired mobility of the lamellar insert in the thickness direction.

[0026] A practical embodiment provides that the socket housing has at least one further contacting device, in particular a crimp or plug connection, contact tabs, or contact pins. To transmit the electrical current transferred from the flat contact plug to the flat contact socket, the flat contact socket according to the invention typically has at least one further contacting device by means of which the socket housing is connected to an electrical conductor, a printed circuit board, or an electrical component. For connection to flexible conductors or busbars, simple crimp connections can be provided in the conventional manner, with the connection to a flexible conductor offering additional degrees of freedom with regard to movement and compensation for misalignment of the plugging elements.For connecting the socket housing to circuit boards, bus bars, and contact rails, rigid connections such as contact tabs or contact pins, for example SMD, THT, and EON connectors, but also simple plug connectors, are typically used. However, the rigid connection of the additional contacting device increases the risk of misalignment between the components of the connector according to the invention, resulting in poor mating behavior, poor electrical contact of the connector, and higher transmission resistance. Therefore, in rigid contacting devices, the mobility of the lamella insert is of particular importance.

[0027] For secure and precise positioning of the cage-shaped lamella insert, the socket housing can incorporate locking elements for positioning and permanently securing the lamella insert within the cuboid hollow of the socket housing. This prevents the lamella insert from being unintentionally pulled out of the socket housing, for example, when disconnecting the flat contact plug from the flat contact socket. Furthermore, such locking elements prevent the lamella insert from unintentionally loosening or falling out of the socket housing under vibration or extreme environmental conditions.

[0028] It is advantageous if the locking elements are designed as inwardly curved housing tabs, whereby the inwardly curved housing tabs bear against the cage-shaped lamellar insert and prevent the lamellar insert from being unintentionally pulled out of the mold, and wherein the housing tabs are preferably curved inwards at an angle between 30° and 60°, particularly between 40° and 50°. Inwardly curved housing tabs are a simple and reliable solution for preventing the lamellar insert from being unintentionally pulled out of the mold. Inwardly curved housing tabs can relatively easily overlap with the rear edge of the lamellar insert and bear against it accordingly, thus ensuring secure positioning and permanent protection against unintentional removal. Alternatively, other locking elements can also be used.

[0029] In a practical embodiment of the flat contact socket according to the invention, the cage-shaped lamellar insert can be manufactured as a stamped and bent component, in particular as a stamped and bent contact cage. Manufacturing a suitable lamellar insert or a suitable contact cage as a stamped and bent component enables automated and cost-effective production of the lamellar insert from a simple sheet or strip of metal with good and consistent quality. In a stamped and bent cage-shaped lamellar insert, the butt edges between the bent ends of the stamped sheet metal part can run essentially parallel to the axis of insertion and be positively or materially interlocked with one another in the area of ​​the circumferential edge or the front and rear edges, in particular welded together.

[0030] To provide good mechanical and electrical properties, the cage-shaped lamellar insert can be made of a metal material, preferably a copper alloy, in particular a low-alloy copper material, for example, a high-performance alloy with a conductivity of less than 32 MS / m, which provides high strength in addition to good electrical and thermal conductivity. Preferably, the conductivity of the high-performance alloy can be between 5 MS / m and 32 MS / m. A lamellar insert produced as a stamped-bent component can be conveniently manufactured directly from a sheet or strip of metal that can be fed directly into a stamping machine.

[0031] A favorable embodiment provides that the bushing housing is made of a metal material and manufactured as a stamped-bent component, wherein the metal material of the bushing housing is preferably a lower-grade material than the metal material of the lamellar insert. A metal bushing housing enables reliable and trouble-free electrical contact and cost-effective manufacturing as a stamped-bent component, whereby, in view of the low mechanical stress on the bushing housing, a cost-effective material with lower requirements for strength and bending properties can be used. A variant of the bushing housing provides that locking elements are provided on the end faces of the stamped part of the bushing housing to positively engage the two end faces.Such form-fitting locking elements, for example head-shaped joining projections and associated joining recesses on the end faces of the flat stamped part, enable a firm and permanent connection of the end-face butt edges of the bushing housing directly during the bending process, so that an additional material-bonded connection and additional processing steps can be dispensed with.

[0032] The present invention further relates to a method for manufacturing a one-piece cage-shaped lamellar insert for a flat contact socket described above. This method comprises punching a flat stamped part from a metal sheet, including a contour of a lamellar area as well as a front edge and a rear edge, the subsequent embossing of the flat stamped part to form inwardly projecting, resilient inner lamellae and outwardly projecting, resilient outer lamellae, the optional setting of the insertion tabs and stop tabs, and the final bending or rolling of the embossed stamped part into a cage-shaped lamellar insert and joining the butt edges of the front edge and optionally the rear edge, preferably by welding or brazing, to form a closed frame.This stamping-bending process allows for the very cost-effective production of lamellar inserts for flat contact sockets, suitable for receiving and electrically contacting a flat contact plug. Stamping-bending processes enable the fully automated production of cage-shaped lamellar inserts and, if necessary, the associated socket housings, and require no additional components in the connector area or for further electrical contact with conductors or components. The contour of the lamellar areas cut out during stamping can be considered a flat preform of the contact areas for the flat contact plug and socket housing, from which the inner and outer lamellae are created by the subsequent embossing and bending of the flat stamped part.During the stamping process of the flat die-cut part, the alternating inner and outer lamellae, running side by side, are bent towards the inside or outside of the cage-shaped lamella insert. Stamping the flat die-cut part from a sheet or strip of metal does not automatically include the final separation of the part from the strip. The actual cutting or punching of the part can also be carried out after stamping to form the lamellae, which allows for better guidance of the flat die-cut part during the stamping process. The flat die-cut part is defined as the unwound, unstamped shape of the lamella insert.

[0033] Furthermore, the invention relates to a method for manufacturing a flat contact socket with a socket housing and a one-piece cage-shaped lamellar insert. This method comprises the above-described manufacturing of a one-piece cage-shaped lamellar insert, as well as the manufacturing of a socket housing with a cuboid hollow form using a stamping-bending process, the insertion of the lamellar insert through a housing opening of the cuboid hollow form of the socket housing, and the securing of the cage-shaped lamellar insert in the cuboid hollow form by means of locking elements provided on the socket housing. With such a method, an improved flat contact socket for a flat contact connector can be manufactured cost-effectively, enabling both a simple plug-in connection with a flat contact plug and ensuring reliable current transmission.

[0034] Non-limiting embodiments of the present invention are explained in more detail below with reference to exemplary drawings.

[0035] They show:

[0036] Figure 1A shows a perspective view of a flat contact socket according to the invention.

[0037] Figure 1B shows a perspective view of the flat contact socket from Figure 1A with a flat contact plug inserted into it.

[0038] Figure 2 is a perspective exploded view of the flat contact socket from Figure 1A.

[0039] Figure 3A shows a top view of the flat contact socket from Figure 1A.

[0040] Figure 3B shows a bottom view of the flat contact socket from Figure 1A.

[0041] Figure 4A shows a longitudinal section through the flat contact socket from Figure 1A in a perspective view,

[0042] Figure 4B shows a section through the flat contact socket from Figure 1A along line IV-IV from Figure 3A in a side view.

[0043] Figure 5A is a perspective view of the lamellar insert for the flat contact socket from Figure 1A, Figure 5B is a side view of the lamellar insert from Figure 5A in the width direction,

[0044] Figure 5C shows a side view of the lamella insert from Figure 5A in the thickness direction.

[0045] Figure 6A shows a perspective view of a second embodiment of a flat contact socket according to the invention.

[0046] Figure 6B shows an exploded view of the flat contact socket from Figure 6A in a perspective view.

[0047] Figure 6C shows a perspective view of a lamellar insert for the flat contact socket from Figure 6A.

[0048] Figure 7A shows a perspective view of another embodiment of a flat contact socket according to the invention.

[0049] Figure 7B shows an exploded view of the flat contact socket from Figure 7A in a perspective view.

[0050] Figure 7C shows a perspective view of a lamellar insert for the flat contact socket from Figure 7A.

[0051] Figure 8A shows a perspective view of another embodiment of a flat contact socket according to the invention and

[0052] Figure 8B is an exploded view of the flat contact socket from Figure 8A in a perspective view.

[0053] Figure 1A shows a perspective view of a flat contact socket 1 according to the invention, which is suitable for electrical contacting of high-performance components, particularly in high-voltage systems. The flat contact socket 1 has a socket housing 2 and a one-piece, cage-shaped lamellar insert 3, which is received in a cuboid-shaped hollow form 4 of the socket housing 2. The lamellar insert 3 is in electrical contact with the inner wall 5 of the socket housing 2 in the region of the hollow form 4. At an end of the socket housing 2 opposite the lamellar insert 3, several contact tabs 6 are provided, which extend outwards from the socket housing 2 and are intended for electrical contact with a busbar or an electrical component. The socket housing 2 is made of sheet metal and is manufactured by a stamping-bending process.One end face 32 of the stamped sheet metal material has a joining recess 7 and a second end face 32 has a joining projection 8, which engage precisely during the bending process and lock the butt edges of the finished bent bushing housing 2. Alternatively, straight butt edges of the finished bent bushing housing 2 can also be joined together by line welding.

[0054] On the short sides in the thickness direction D of the bushing housing 2, in the area of ​​the housing opening 10 of the hollow form 4, there is a recess 9 in the edge of the bushing housing 2 for the lateral reception of the stop tabs 15 of the lamellar insert 3. At the opposite, lower end of the short thick sides of the bushing housing 2, an inwardly bent housing tab 11 is provided as a locking element for positioning and permanently securing the lamellar insert 3 in the cuboid hollow form 4 of the bushing housing 2. The inwardly bent housing tabs 11 undercut the rear edge 13 of the lamellar insert 3, thus preventing the lamellar insert 3 from being unintentionally pulled out or falling out of the hollow form 4 of the bushing housing 2.On the front edge 12 of the lamella insert 3, which can be seen inside the hollow form 4, in addition to the stop tabs 15 bent outwards on the side walls, there are also insertion tabs 14 inclined outwards on the side walls.

[0055] Figure 1B shows a perspective view of the flat contact socket 1 with the socket housing 2 and the lamellar insert 3 contained therein. In this illustration, a flat contact plug 22, rectangular in cross-section, is inserted into the lamellar insert 3. The flat contact plug 22 has a width b and a thickness d in the insertion direction E, where the aspect ratio of width b to thickness d is at least 2 and usually greater than 5. The width b and the thickness d of the flat contact plug 22 define a width direction B extending in the direction of width b and a thickness direction D extending in the direction of thickness d for the socket housing 2 and the lamellar insert 3. Due to the rectangular shape of the flat contact plug 22, the width direction B and the thickness direction D are perpendicular to each other and each perpendicular to the insertion direction E of the flat contact plug 22 into a flat contact opening 23 of the lamellar insert 3.

[0056] Figure 2 shows a perspective exploded view of the flat contact socket 1 according to the invention from Figure 1A. In this view, the socket housing 2, produced in a stamping-bending process, is again shown with a housing opening 10, a cuboid hollow form 4, outwardly bent contact tabs 6 with central slots 21, a joining connection consisting of a joining recess 7 and a joining projection 8 at the butt edges, as well as the recesses 9 and the housing tabs 11 on the top side of the socket housing 2 in the thickness direction D.

[0057] The entire lamellar insert 3 can also be seen in the exploded view in Figure 2. The lamellar insert 3 consists of the front edge 12, with a stop tab 15 projecting on each of its two sides in the thickness direction D (the thick sides), extending at an angle outwards, and two slightly outwardly curved insertion tabs 14 on each of its two sides in the width direction B (the width sides), a rear edge 13, which, in the assembled state, undercuts the housing tabs 11 of the bushing housing 2, and two inner lamellae 16 and three outer lamellae 17 on each width side. The inner lamellae 16 extend along the sides in the width direction B from the front edge 12 to the rear edge 13 and are curved inwards to connect with the front edge 12 and the rear edge 13. The three outer lamellae 17 extend from the front edge 12 towards the rear edge 13 and project outwards.The outer lamellae 17 are arranged alternately with the inner lamellae 16. Unlike the inner lamellae 16, which extend between the front edge 12 and the rear edge 13, the outer lamellae 17 are attached only at the front edge 12 and are resiliently bent outwards there. This ensures that, when the flat contact socket 1 is assembled, the outer lamellae 17 make electrical contact with the inner wall 5 of the socket housing 2 at a respective contact point 18 of the outer lamellae 17. The lamella insert 3 is also manufactured using a stamping-bending process, with at least the front edge 12 and optionally also the rear edge 13 being welded together at the respective butt joints 19 to make the lamella insert 3 stable and resistant to warping. The front edge 13 forms a flat contact opening 23 for receiving the flat contact plug 22.

[0058] Figure 3A shows a top view of the flat contact socket 1 from Figure 1A. This top view clearly shows the arrangement of the lamellar insert 3 in the hollow form 4 of the socket housing 2. As shown in Figure 2, during assembly of the flat contact socket 1, the lamellar insert 3 is inserted through the housing opening 10 into the cuboid hollow form 4 of the socket housing 2. The stop tabs 15 then rest on the recesses 9 on the thick sides in the thickness direction D of the socket housing 2. On the wide sides in the width direction B, both the inclined insertion tabs 14 and the outer lamellae 17 behind them are visible, which are in contact with the inner wall 5 of the socket housing 2 at their contact points 18 in the hollow form 4.Between the outer lamellae 17, on the inside of the lamella insert 3, two inner lamellae 16 are arranged on each side of the front edge 12 in the width direction B, extending in one piece to the rear edge 13. A weld 20 is visible between the butt edges 19 of the lamella insert 3 at the front edge 12, forming the front edge 12 as a stable ring. The contact tabs 6, bent outwards at their lower end, are also visible on the bushing housing 2 and are provided with a slot 21 for improved contact.

[0059] A bottom view of the flat contact socket 1 from Figure 1A is shown in Figure 3B. Besides the contact tabs 6 extending outwards from the lower end of the hollow form 4 of the socket housing 2, with their associated slots 21, the inwardly curved housing tabs 11 for securing the lamellar insert 3 in the socket housing 2 can be seen on the flat sides in the thickness direction D. The housing tabs 11 undercut the rear edge 13 or are supported above the rear edge 13, thus preventing the lamellar insert 3 from being unintentionally pulled out or falling out. The stop tabs 15, which bear against the recesses 9 on the top of the socket housing 2, prevent the lamellar insert 3 from falling out through the underside of the socket housing 2.The butt edges 19 of the rear edge 13 are also firmly connected to each other by means of a weld connection 20, so that the rear edge 13 is also formed as a stable ring.

[0060] Between the rear edge 13 and the inner wall 5 of the hollow form 4, three outer lamellae 17 are provided on each side. These are firmly connected to the front edge 12 and bear resiliently against the inner wall 5. Within the rear edge 13, two inner lamellae 16 are arranged on each side in the lateral direction B. These are connected to the front edge 12 and the rear edge 13 and extend inwards between them. In a connected state, the flat contact connector 22 is located between the opposing inner lamellae 16. The flat contact connector 22 pushes the inner lamellae 16 outwards, and the preload of the inner lamellae 16 ensures reliable electrical contact via the inner lamellae 16, the front edge 12, the outer lamellae 17, the inner wall 5 of the hollow form 4, and the socket housing 2, up to the outwardly projecting contact lugs 6.

[0061] Figure 4A shows a longitudinal section in perspective view through the flat contact socket 1 from Figure 1A. In this longitudinal section in the width direction B through the flat contact socket 1, the contact surfaces of the stop tabs 15 of the lamellar insert 3 in the recesses 9 of the socket housing 2 in the ribbed sides in the thickness direction D are clearly visible. The stop tabs 15, which are angled outwards from the front edge 12 of the lamellar insert 3, hold the lamellar insert 3 in the hollow form 4 of the socket housing 2 and prevent the lamellar insert 3 from being inserted further into the socket housing 2 during assembly and when a flat contact plug 22 is inserted into the flat contact opening 23.

[0062] The inwardly curved housing tabs 11 on the flat sides of the bushing housing 2 undercut each other or, after assembly, rest on the rear edge 13 of the lamellar insert 3, thus preventing the lamellar insert 3 from being pulled out or falling out of the housing opening 10. On the front edge 12, the two outwardly curved insertion tabs 14 are visible on the wider side; these are arranged offset to the outside relative to the inner lamellae 16. The inner lamellae 16 of the lamellar insert 3 each extend from the front edge 12 to the rear edge 13. The two inner legs 33 of the inner lamellae 16 of the lamellar insert 3 are each connected to the front edge 12 and the rear edge 13.The two inner legs 33 project inwards from the front edge 12 and the rear edge 13 and form an elongated contact section 25 at their apex, which makes electrical contact with an inserted flat contact plug 22. The inwardly pre-bent inner legs 33 of the inner lamellae 16 ensure sufficient contact pressure on the flat contact plug 22 and thus reliable electrical contact.

[0063] Figure 4B shows a side view of a section through the flat contact socket 1 according to the invention from Figure 1A along line IV-IV from Figure 3A. The housing tabs 11 provided on the dieken sides of the socket housing 2 are clearly visible. These tabs are positioned a short distance from the rear edge 13 to allow sufficient clearance for the movement and tilting of the lamella insert 3 within the socket housing 2, despite their overlap with the rear edge 13. In addition to the inner lamellae 16 with their inwardly pre-bent inner legs 33, the differently shaped outer lamellae 17 are also clearly visible in this sectional view.The rear outer lamellae 17 on both sides of the width each have a spring leg 26 arranged at the front edge 12. This spring leg 26 has a smaller inclination relative to the insertion direction E and is longer than the spring legs 26 of the middle outer lamellae 17, which are arranged in the section plane IV-IV. The middle outer lamellae 17 are each shorter and bent outwards at a greater inclination relative to the insertion direction E. Accordingly, the contact points 18 of the rear outer lamellae 17 and the middle outer lamellae 17 are located at different heights (in the insertion direction E) on the inner wall 5 of the bushing housing 2. The contact point 18 of the front outer lamellae 17 is located above the contact section 25 of the inner lamellae 16, and the contact point 18 of the middle outer lamellae 17 is located below the contact sections 25 of the inner lamellae 16.

[0064] The different heights of the contact points 18 of the outer lamellae 17 in the insertion direction E are also clearly visible in the perspective view of the lamella insert 3 in Figure 5A. The spring legs 26 of the two outer outer lamellae 17 arranged on the wide side of the lamella insert 3 are longer and inclined less outwards in the insertion direction E than the spring leg 26 of the middle outer lamellae 17. To ensure the best possible and most reliable electrical contact between the outer lamellae 17 and the inner wall 5 of the bushing housing 2, caps 27 are provided at the contact points 18 of the outer lamellae. The caps 27, which project from the contact points 18 in a spherical segment shape, increase the contact pressure against the inner wall 5 to enable a permanent and reliable electrical contact.The butt edges 19 at the front edge 12 and rear edge 13 are each connected by a weld 20 to improve the stiffness of the front edge 12 and the rear edge 13. On the front edge 12, the outwardly inclined insertion tabs 14 can again be seen on the upper wide sides, and the outwardly angled stop tabs 15 on the sill sides.

[0065] In the side view of the lamella insert 3 shown in the width direction B in Figure 5B, the different heights of the contact points 18 of the two outer lamellae 17 and the middle outer lamella 17 are clearly visible. The two outer lamellae 17 each have a long spring leg 26, while the middle outer lamella 17 has a short spring leg 26. As a result, the contact point 18 of the middle outer lamella 17, viewed from the front edge 12, lies above the contact sections 25 of the inner lamellae 16, or above the apex points of the two inner legs 33 of the inner lamellae 16, while the contact points 18 of the two outer lamellae 17 lie below the contact sections 25 of the inner lamellae 16. The outer lamellae 17 begin at the front edge 12 and extend outwards in a curved direction towards the rear edge 13.In contrast, the inner lamellae are connected to the front edge 12 and the rear edge 13 and project inwards, see also the side view of the lamella insert 3 in the thickness direction D in Figure 5C. The distance between the inner lamellae 16 projecting inwards from both sides at the height of the apex or contact section 25 is less than the thickness d of a corresponding flat contact connector 22, so that in a connected state, the inner lamellae 16 exert sufficient pressure on the flat contact connector 22 in the area of ​​the contact sections 25 for reliable electrical contact.

[0066] As can be clearly seen in Figure 5C, the spherical segment-shaped caps 27 provided at the contact point 18 of the outer lamellae 17 project outwards to enable reliable electrical contact with the inner wall 5 of the socket housing 2. Following the contact points 18 of the outer lamellae 17, the spring leg 26 connected to the front edge 12 transitions into a free end 28, which is bent inwards relative to the spring leg 26 and facilitates the insertion of the lamella insert 3 into the hollow form 4 during assembly of the flat contact socket 1.

[0067] When a flat contact connector 22 is inserted into the flat contact opening 23 of the lamella insert 3, the inwardly projecting inner lamellae 16 are slightly stretched outwards against their preload, resulting in reliable electrical contact with the flat contact connector 22 at the contact sections 25 of the inner lamellae 16. Due to the stretching of the inner lamellae 16, the rear edge 13, which is also connected to the inner lamellae 16, moves in the direction of insertion E of the flat contact connector 22, slightly increasing the distance between the housing tabs 11 and the rear edge 13. The outer lamellae 17, which are spring-loaded outwards and bear against the inner wall 5 of the socket housing 2 with their caps 27, then establish electrical contact with the socket housing 2 via the front edge 12.If the flat contact connector 22 is offset from the flat contact opening 23 of the lamellar insert 3, the flat contact connector 22 is guided towards the flat contact opening 23 by the insertion tabs 14. Simultaneously, the lamellar insert 3 moves against the preload of the outer lamellae 17 in the direction of the offset between the flat contact connector 22 and the flat contact opening 23, the movement of the lamellar insert 3 in the thickness direction D being limited by the stop tab 15 located in the recess 9 at the upper edge of the socket housing 2.In addition, the floating mounting of the lamellar insert 3 via the stop tabs 15 resting in the recesses 9 on the diene sides of the socket housing 2 and the outer lamellae 17 spring-loaded against the inner wall 24 of the socket housing 2 allows the lamellar insert 3 to be inclined in the socket housing 2, which improves both the guidance of the flat contact plug 22 when inserted into the flat contact opening 23 of the lamellar insert 3 and increases the permissible size of the offset between flat contact plug 22 and flat contact opening 23.

[0068] A second embodiment of a flat contact socket 1 according to the invention is shown in Figure 6A. In this perspective view of the assembled flat contact socket 1, the lamellar insert 3 arranged in the hollow form 4 of the socket housing 2 can again be seen. The lamellar insert 3 is in electrical contact with the inner wall 5 of the socket housing 2 within the cuboid hollow form 4. In contrast to the first embodiment, the socket housing 2 has four contact lugs 6 with slots 21 on each of its two sides for fastening and electrically connecting the socket housing 2 to a busbar or an electrical component.This bushing housing 2 is also manufactured by a stamping-bending process and has a joining recess 7 or a joining projection 8 on the end faces 32 of the stamped sheet material. These engage precisely during the bending process to lock the end faces of the finished bent bushing housing 2 together. A recess 9 is provided on each of the ribbed sides of the housing opening 10 of the bushing housing 2, in which the stop tabs 15 of the lamellar insert 3 are arranged. Here, too, an inwardly bent housing tab 11 is provided in the lower areas of the ribbed sides of the bushing housing 2. This tab ends above the rear edge 13 of the lamellar insert 3 and enables secure positioning and permanent arrangement of the lamellar insert 3 in the cuboid hollow form 4 of the bushing housing 2.

[0069] As can be seen more clearly in the exploded view of the second embodiment of a flat contact socket 1 in Figure 6B, the lamellar insert 3 is wider and allows for the reception of a flat contact plug 22 with a greater width B. This lamellar insert 3 has, on each side in the width direction B, four outer lamellae 17 that are resiliently bent outwards from the front edge 12 and three inwards bent inner lamellae 16 arranged between them. The inner lamellae 16 are connected to the front edge 12 and the rear edge 13 by their inner legs 33.As can also be seen in the perspective view of the lamella insert 3 in Figure 6C, the two outer lamellae 17 each have a longer spring leg 26, which is bent outwards at a small angle from the insertion direction E, and the two inner outer lamellae 17 each have a shorter spring leg 26 attached to the front edge 12, which is bent outwards at a larger angle relative to the insertion direction E, in order to ensure the most uniform possible preload of the contact points 18 of the outer lamellae 17 on the inner wall 5 and the most uniform possible distance in the thickness direction D relative to the lamella insert 3. Accordingly, the contact points 18 of the two outer lamellae 17 are also located below the contact sections 25 of the inner lamellae 16 in the insertion direction E, and the contact points 18 of the two inner outer lamellae 17 are located above the contact sections 25 of the inner lamellae 16.

[0070] In the second embodiment of a flat contact socket 1 according to the invention, shown in Figures 6A-6C, two insertion tabs 14 projecting outwards and inclined in the opposite direction to the insertion direction E are again provided at the front edge 12. Furthermore, both the front edge 12 and the rear edge 13 are connected at the butt edges 19 by means of a weld 20 in order to make the lamellar insert 3 stable and resistant to twisting.

[0071] Figures 7A-7C show another embodiment of a flat contact socket 1 according to the invention. As can be seen in the perspective views of the socket housing 2 in Figures 7A and 7B, the lower end of the socket housing 2 has four contact pins 24 on each side, which enable simple and reliable contacting of the flat contact socket 1 with electrical components. Furthermore, the socket housing 2 is designed like the elongated socket housing 2 of the second embodiment of a flat contact socket 1 according to the invention shown in Figures 6A-6C. Likewise, the lamella insert 3 is designed in the same way, with four outer lamellae 17 and three inner lamellae 16 arranged alternately on each side.Furthermore, this lamella insert has three outwardly angled limiting tabs 29 at the front edge 12 between the outwardly inclined insertion tabs 14, which limit the movement of the lamella insert 3 in the thickness direction D.

[0072] Figures 8A and 8B show another embodiment of a flat contact socket 1 according to the invention. In contrast to the previous embodiments, the socket housing 2 has four EON contact pins 30 at its lower end on each side, by means of which the flat contact socket 1 can be easily mounted on a circuit board and electrically connected to it. Additionally, spacers 31 are provided at the outer ends of the sides to ensure the correct positioning of the EON contact pins 30 in the corresponding circuit board. The remaining structure of the socket housing 2 and the entire lamella insert 3 corresponds to the structure of the first embodiment of a flat contact socket 1 from Figures 1A-5C, and therefore reference is made to the detailed description of that embodiment.

[0073] In the manufacture of a flat contact socket 1 according to the invention, the socket housing 2 and the lamellar insert 3 are first manufactured separately, each using a stamping-bending process. In the case of the socket housing 2, the contour of the socket housing 2, including the recesses 9 on the top sides, as well as the joining recess 7 and the joining projections 8 on the end faces 32 of the flat stamped part, is first stamped out using the stamping-bending process. In a second step, the outwardly bent contact tabs 6 are formed into their position relative to the socket housing 2. The stamped part is then bent into the shape of the socket housing 2, with the joining projections 8 engaging precisely in the joining recess 7 to lock the end faces 32 of the stamped part together.The bushing housing 2 can be made of a metal material with lower strength and lower elasticity than the lamellar insert 3. The inwardly bent housing tabs 11 are only bent inwards after the cage-shaped lamellar insert 3 has been inserted, as otherwise the housing tabs 11 could damage the lamellar insert 3. Alternatively, the bushing housing 2 can also be manufactured using a different production process, for example, as an injection-molded part.

[0074] For the production of the lamellar insert 3 of a flat contact bushing 1 according to the invention, a further stamping-bending process is used, wherein here too a flat stamped part is first stamped from a sheet of metal, corresponding to the developed contour of the lamellar insert 3 including the lamellae 16, 17 as well as the front edge 12 and the rear edge 13. Subsequently, the flat stamped part is embossed to form both the inwardly projecting inner lamellae 16 connected to the front edge 12 and the rear edge 13 and the outwardly projecting, resiliently formed outer lamellae 17. In addition, the insertion tabs 14 and stop tabs 15 provided on the front edge 12 and, if applicable, limiting tabs 29 are embossed according to the intended inclination and shape.Subsequently, the stamped part is bent into the cage-shaped lamellar insert 3, and the butt edges 19 of the front edge 12 and the rear edge 13 are joined by welding or brazing to form a closed frame. A copper alloy with high strength and good electrical and thermal conductivity is preferably used as the material for manufacturing the lamellar insert 3; this alloy can be fed directly to a stamping and bending device as sheet metal or strip metal.

[0075] During the assembly of a flat contact socket 1 according to the invention, the one-piece cage-shaped lamellar insert 3 is inserted through the housing opening 10 into the cuboid hollow form 4 of the socket housing 2 until the stop tabs 15 are arranged in the recesses 9 on the flat sides of the socket housing 2 and the rear edge 13 has passed the housing tabs 11 on the flat sides of the socket housing 2. The housing tabs 11 are then bent inwards and, by means of the undercut with the rear edge 13, secure the position of the cage-shaped lamellar insert 3 in the cuboid hollow form 4 of the socket housing 2.

[0076] Reference symbol list

[0077] 1 flat contact socket

[0078] 2 socket housings

[0079] 3 slat insert

[0080] 4 cuboid hollow forms

[0081] 5 Inner wall

[0082] 6 contact flags

[0083] 7 Joining recess

[0084] 8 joining lead

[0085] 9 In-depth study

[0086] 10 Case opening

[0087] 11 Housing tab

[0088] 12 front edge

[0089] 13 rear edge

[0090] 14 insertion tabs

[0091] 15 stop tabs

[0092] 16 internal slats

[0093] 17 outer slats

[0094] 18 Contact Point

[0095] 19 butt joints

[0096] 20 welded joints

[0097] 21 slots

[0098] 22 flat contact connectors

[0099] 23 Flat contact opening

[0100] 24 contact pins

[0101] 25 contact sections

[0102] 26 spring legs

[0103] 27 calottes

[0104] 28 free ending

[0105] 29 limit tabs

[0106] 30 EON contact pins

[0107] 31 spacers

[0108] 32 end faces

[0109] 33 Inner thigh b width

[0110] B Width direction d Thickness

[0111] D Thickness direction

[0112] E Insertion direction

Claims

Claims 1. Flat contact socket (1) for a rectangular flat contact plug (22) comprising a socket housing (2) and a one-piece cage-shaped lamellar insert (3) for receiving and electrically contacting the flat contact plug (22), wherein the rectangular flat contact plug (22) has a thickness (d) and a width (b) that is at least twice the thickness, which define a thickness direction (D) and a width direction (B) for the flat contact socket (1) and an insertion direction (E) of the flat contact plug (22) oriented perpendicular to the thickness direction (D) and width direction (B), the cage-shaped lamellar insert (3) being received in a cuboid hollow form (4) of the socket housing (2) and being provided for electrically contacting the socket housing (2), wherein the lamellar insert (3) has at least one substantially circumferential rim (12),a flat contact opening (23) defined by the circumferential edge (12) for inserting the flat contact plug (22) and several inner lamellae (16), wherein the inner lamellae (16) are connected to the circumferential edge (12), project inwards relative to the circumferential edge (12) and are provided for the electrical contacting of the flat contact plug (22), characterized in that the lamella insert (3) is resiliently supported in the hollow form (4) of the socket housing (2) such that at least the circumferential edge (12) of the lamella insert (3) is movable relative to the socket housing (2) in the thickness direction (D) and / or the width direction (B), preferably at least in the thickness direction (D).

2. Flat contact socket (1) according to claim 1 , characterized in that the mobility of the spring-supported lamellar insert (3) relative to the socket housing (2) in the thickness direction (D) is at least 25%, preferably at least 50%, in particular at least 75% of the thickness of the associated flat contact plug (22).

3. Flat contact socket (1) according to claim 1 or 2, characterized in that the mobility of the spring-supported lamellar insert (3) relative to the socket housing (2) in the width direction (B) is at least 3%, preferably at least 5% of the width (b) of the associated flat contact plug (22).

4. Flat contact socket (1) according to one of claims 1 to 3, characterized in that the lamellar insert (3) is resiliently supported in the hollow form (4) of the socket housing (2) such that the lamellar insert can be tilted in the insertion direction (E) relative to the width sides of the socket housing (2), preferably by at least 3°, in particular between 5° and 10° to the insertion direction (E).

5. Flat contact socket (1) according to one of claims 1 to 4, characterized in that several outwardly projecting, resiliently prestressed outer lamellae (17) are provided for the resilient support of the movably arranged lamellar insert (3) and its electrical contacting with the socket housing (2), which are connected to the circumferential edge (12) of the lamellar insert (3), wherein at least one outer lamella (17), preferably at least two outer lamellae (17) per side, are provided on each side width of the cage-shaped lamellar insert (3).

6. Flat contact socket (1) according to claim 5, characterized in that the resiliently pre-tensioned outer lamellae (17) are in electrical contact at a contact point (18) with an inner wall (5) of the socket housing (2) and the contact point (18) of at least one outer lamella (17) is designed as an outwardly projecting dome (27), wherein preferably all outwardly projecting, resiliently pre-tensioned outer lamellae (17) have a contact point (18) designed as a dome for electrical contact with an inner wall (5) of the socket housing (2).

7. Flat contact socket (1) according to one of claims 1 to 6, characterized in that the circumferential edge (12) of the cage-shaped lamellar insert (3) is formed as a closed ring.

8. Flat contact socket (1) according to one of claims 1 to 7, characterized in that the cage-shaped lamellar insert (3) has a front edge (12) forming the circumferential rim (12) and a rear edge (13), wherein the inner lamellae (16) preferably extend from the front edge (12) to the rear edge (13) and are in particular firmly connected to the front edge (12) and the rear edge (13), and wherein the outer lamellae (17) preferably are arranged only at the front edge (12) or the rear edge (13), in particular only at the front edge (12).

9. Flat contact socket (1) according to claim 8, characterized in that the inner lamellae (16) are attached to the front edge (12) and rear edge (13), wherein the inner legs (33) of the inner lamellae (16) attached to the front edge (12) and rear edge (13) are each bent inwards, preferably in an angle range with respect to an insertion direction (E) between 10° and 25°, in particular between 15° and 20°.

10. Flat contact socket (1) according to claim 9, characterized in that a contact section (25) of the inner lamellae (16) is arranged at the apex between the inwardly bent inner legs (33) in a region between 40% and 60% of the distance between the front edge (12) and the rear edge (13), in particular approximately in the middle between the front edge (12) and the rear edge (13).

11. Flat contact socket (1) according to one of claims 1 to 10, characterized in that at least two inwardly projecting inner lamellae (16) are provided on each wide side of the lamella insert (3).

12. Flat contact socket (1) according to claim 11 , characterized in that the at least two inner lamellae (16) provided on each side of the lamella insert (3) have a different contact height relative to the flat contact plug (22) in the insertion direction of the flat contact plug (22).

13. Flat contact socket (1) according to one of claims 5 to 12, characterized in that at least two outwardly projecting, resiliently prestressed outer lamellae (17) are provided on each wide side of the lamella insert (3), wherein the at least two outer lamellae (17) are preferably attached to a front edge (12), and wherein the at least two outer lamellae (17) are in electrical contact with an inner wall (5) of the socket housing (2).

14. Flat contact socket (1) according to claim 13, characterized in that the at least two outer lamellae (17) on each width side in the insertion direction (E) of the flat contact plug have a different contact height relative to the socket housing (2), wherein the different contact heights of the at least two outer lamellae (17) of each width side are preferably arranged above and below a contact height of the associated inner lamellae (16) with a flat contact plug (22).

15. Flat contact socket (1) according to claim 14, characterized in that the at least two outer lamellae (17) of each width side are bent outwards differently, wherein on each width side a spring leg (26) of a first outer lamella (17) attached to the front edge (12) preferably has a smaller bending angle than a spring leg (26) of a second outer lamella (17) attached to the front edge (12).

16. Flat contact socket (1) according to claim 15, characterized in that the spring leg (26) of the first outer lamella (17) is bent outwards in a range between 10° and 30°, preferably between 15° and 25°, relative to the insertion direction (E), and wherein a free end (28) of the first outer lamella (17), which abuts the spring leg (26) at a contact point (18) of the first outer lamella (17) with the inner wall (5) of the socket housing (2), is bent inwards relative to the spring leg (26) of the first outer lamella (17), in particular in a range between 10° and 30°, preferably between 15° and 25°.

17. Flat contact socket (1) according to claim 15 or 16, characterized in that the spring leg (26) of the second outer lamella (17) is bent outwards in a range between 30° and 50°, preferably between 35° and 45°, relative to the insertion direction (E), and wherein a free end (28) of the second outer lamella (17), which abuts the spring leg (26) at a contact point (18) of the second outer lamella (17) with the inner wall (5) of the socket housing (2), is bent inwards relative to the spring leg (26) of the second outer lamella (17), in particular in a range between 5° and 25°, preferably between 10° and 20°.

18. Flat contact socket (1) according to one of claims 8 to 17, characterized in that insertion tabs (14) are provided on the front edge (12) angled outwards and projecting in the opposite direction of insertion (E), preferably at least two insertion tabs (14) are provided on each side of the lamella insert (3), and wherein the insertion tabs (14) are angled outwards, in particular at an angle between 10° and 45°, preferably between 20° and 30°.

19. Flat contact socket (1) according to one of claims 8 to 18, characterized in that at least one stop tab (15) is provided on each of the front edges (12) of the lamella insert (3), wherein the stop tabs (15) are bent outwards from the front edge (12) of the lamella insert (3), in particular bent outwards in an angle range between 80° and 100°.

20. Flat contact socket (1) according to claim 19, characterized in that a lateral receptacle for the stop tabs (15) is provided on each of the sides extending in the thickness direction (D) of a housing opening (10) of the cuboid hollow form (4) of the socket housing (2), preferably a recess (9) of the socket housing (2) on the sides extending in the thickness direction (D) of the housing opening (10), and wherein in particular the length of the lateral receptacles, preferably of the recesses (9), in the thickness direction (D) is greater than the width of the stop tabs (15) in the thickness direction, in particular by a factor of 1.2 to 2.5, preferably by a factor of 1.3 to 1.

9.

21. Flat contact socket (1) according to one of claims 1 to 20, characterized in that the socket housing (2) has at least one further contacting device, in particular a crimp or plug connection, contact tabs (6) or contact pins (24).

22. Flat contact socket (1) according to one of claims 1 to 21, characterized in that the socket housing (2) has locking elements for positioning and / or arranging the lamellar insert (3) in the cuboid hollow form (4) of the socket housing (2).

23. Flat contact socket (1) according to claim 22, characterized in that the locking elements are designed as inwardly bent housing tabs (11), wherein the inwardly bent housing tabs (11) are supported on the lamellar insert (3) or undercut the lamellar insert (3) to prevent unintentional withdrawal of the lamellar insert (3) from the cuboid hollow form (4), and wherein the housing tabs (11) are preferably bent inwards in an angle range between 30° and 60°, in particular between 40° and 50°.

24. Flat contact socket (1) according to one of claims 1 to 23, characterized in that the cage-shaped lamellar insert (3) is manufactured as a stamped and bent component, in particular as a stamped and bent contact cage.

25. Flat contact socket (1) according to one of claims 1 to 24, characterized in that the lamellar insert (3) is made of a metal material, preferably of a copper alloy, in particular of a low-alloy copper material.

26. Flat contact socket (1) according to claim 25, characterized in that the socket housing (2) is made of a metal material and is manufactured as a stamped-bent component, wherein the metal material of the socket housing (2) is preferably a lower-grade material than the metal material of the lamellar insert (3).

27. Flat contact socket (1) according to claim 26, characterized in that the socket housing (2) has locking elements (7, 8) on the end faces (32) of the stamped part in order to connect the two end faces (32) to each other in a form-fitting manner.

28. Method for manufacturing a one-piece cage-shaped lamellar insert (3) for a flat contact socket (1) according to claims 8 to 27, comprising the steps: Stamping a flat stamped part from a sheet of metal including a contour of a lamellar area as well as a front edge (12) and a rear edge (13); Embossing the flat stamped part to form inwardly projecting, resilient inner lamellae (16) and outwardly projecting, resilient outer lamellae (17); Bending the embossed stamped part into a cage-shaped lamellar insert (3); and Joining the butt edges (19) of the front edge (12) and optionally the butt edges (19) of the rear edge (13), preferably by welding or soldering, to form a closed frame.

29. Method for manufacturing a flat contact socket (1), comprising the steps: Manufacturing a one-piece cage-shaped lamellar insert (3) according to the method of claim 28; Manufacturing a bushing housing (2) with a cuboid hollow form (4) using a stamping and bending process; Inserting the lamellar insert (3) through a housing opening (10) of the cuboid hollow form (4) of the bushing housing (2); and Securing the cage-shaped lamellar insert (3) in the cuboid-shaped hollow form (4) by means of securing elements provided on the bushing housing (2).

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