One-piece contact, produced by means of a folding process, for a plug connector

Abstract

Proposed is a contact (10) for a plug connector, wherein the contact (10) has a contact region (11), a block-like region (12) and a connecting region (13) for making contact with an electrical conductor. At least the contact region (11) is formed from two layers of a flat material by means of a folding process. The region (12) adjoining the contact region (11) has a rectangular or circular cross-section. Primary locking means (12.1, 12.2) are incorporated in the block-like region (12). The block-like region (12) has a symmetrical stop (15) pointing toward the contact region (11). Said stop (15) is of encircling form. A symmetrical plane (16) is situated at the rear, pointing toward the connecting region (13). The symmetrical plane (16) is of encircling design. The symmetrical plane (16) is preferably designed as an undercut. The contact (10) consists of a flat, flexible material.

Description

[0001] One-piece contact manufactured by means of a folding process for a connector

[0002] Description

[0003] The invention relates to a contact or contact element for a connector according to the features of the preamble of claim 1.

[0004] Such a contact is arranged in a contact carrier, for which purpose the contact carrier has a contact chamber for each contact. The contact itself is located at the end of a cable. The cable has an electrical conductor that is electrically (for example, by soldering, welding, crimping, or the like) and thus also mechanically connected to the contact. Each contact has corresponding means for primary locking in its contact chamber, and means for secondary locking are also provided. After each contact is arranged in its associated contact chamber in the contact carrier, the carrier can be inserted into a housing to form a finished connector.

[0005] Connectors typically consist of a plug and a mating connector that can be detachably connected and disconnected. It is essential that the connector maintains a reliable connection when the plug is inserted into the mating connector. This requires considering not only external forces, such as tensile and compressive stresses, acting on the entire connector, but also the risk of a contact being pulled out of the plug and becoming detached if the connector or a cable attached to it is pulled forcefully. To effectively prevent this, a secondary locking mechanism is provided in addition to the primary locking mechanism. The primary locking mechanism is often located between the contact and a corresponding internal contour of the contact chamber.This is achieved, for example, by a protruding spring tab on the contact partner, which engages in a corresponding recess in the inner contour of the contact chamber when the contact partner has been correctly positioned in its end position within the contact chamber. Similar to the primary locking mechanism, the secondary locking mechanism secures the contact partner within its contact chamber (see, for example, DE 10 2017 119 643 A1).

[0006] DE 697 10 123 T2 describes a socket-shaped electrical terminal block, obtained from a single electrically conductive metal plate, with a rear area for its crimp connection to an electrical wire, a transition zone, and a cage-shaped front area. The front area consists of a base, two side walls which are provided with guide means for a plug contact during its insertion and with means for securing this cage in the terminal housing, and two upper half-walls, in which the walls of the cage are extended in the area near the transition zone by two angled legs. The legs of the angle can also define an opening with the side walls that allows the passage of a secondary locking device.

[0007] DE 20 2014 106 059 U1 relates to a contact element for connectors with plug-in contacts arranged on the plug-in side and a crimp terminal arranged on the cable-terminal side, comprising at least one primary locking element and at least one secondary locking element. The plug-in contacts and the crimp terminal are offset from each other along their axes. The at least one primary locking element has two locking springs that are spring-loaded transversely to the plug-in direction and arranged symmetrically to a plug-in center plane. The at least one secondary locking element is arranged symmetrically to the plug-in center plane within the contact element and has at least one secondary locking recess extending transversely to the plug-in direction.

[0008] DE 10 2021 132 990 A1 discloses a two-part contact element for electrical connectors. The contact element consists of two distinct parts: a conductor connection part and a contact part, which are mechanically and electrically connected. The conductor connection part is designed as a stamped and bent component and is intended for crimping onto an electrical conductor. The contact part is a turned part made from a solid material. The conductor connection part is stamped from a sheet metal strip, with individual conductor connection parts remaining attached to a connecting strip. A joining area is then formed on the stamped conductor connection part by forming two tabs projecting from either side in a spiral shape through folding, creasing, or rolling the material, and then pressing them together.In addition, two further opposing pairs of tabs are pulled up in a bending process, thereby forming a conductor connection area.

[0009] From DE 10 2015 201 381 A1, a contact element is known which is designed as a one-piece stamped and bent part. The contact element has a detent element for securing the contact element in its contact chamber of the connector. Furthermore, the contact element comprises a first contact spring which extends at least partially into a receiving area of ​​the contact element for contacting a mating contact inserted into the receiving area. It is proposed to assign a second contact spring opposite the first contact spring, which is also formed by the stamped and bent part.

[0010] A connecting element produced by cutting and folding a metal conductor strip is described in DE 601 25 633 Part 2. This connecting element is characterized by the fact that each contact cage has a third tongue that is folded over a base part of the contact cage and fastened to this base part. This improves thermal conductivity.

[0011] It is known to design the contact as a single piece and to manufacture it from a sheet material using a forming process, in particular a stamping and bending process. The contact area consists of a single layer of the sheet material. The means for primary locking (for example, protruding tabs) and for secondary locking (for example, the contact surface of a block-like design) are realized by means of a complex forming process from the sheet material that adjoins the single layer of sheet material, by forming a block.

[0012] Figures 2 and 6 show a one-piece contact of the applicant and a contact element 5, respectively. The one-piece contact 5 has a transition area 5.1 between the base or contact body 5.4 and crimp wings 5.2. The crimp wings 5.2 and the strain relief wings 5.3 are provided as preferred embodiments. A block-shaped body 6 is formed integrally with the contact body 5.4. Primary locking elements 6.1 are located laterally on the side of the block 6. Reference numeral 7 designates a stop or stop surface of the block-shaped body 6 for the primary locking, and reference numeral 8 designates a plane for a secondary locking mechanism (not shown in detail). A contact area of ​​the contact 5 is identified by reference numeral 4. A disadvantage of this is that this one-piece contact 5 (or the one-piece contact element) only forms one mounting position M.

[0013] Furthermore, it is known to design the contact in two parts. For this purpose, two parts are also produced from a flat material in a forming process, preferably a stamping and bending process, and joined together after their production.

[0014] A two-part contact or contact element 1 in Figure 1 consists of a base body 2 and a separate overspring 3. The base or contact body 2 comprises a contact or contact area 2.1, here for example in the form of a blade contact, as well as two opposing crimp wings 2.2 and two opposing strain relief wings 2.3. The overspring 3 is block-shaped and has two primary locking elements designated with the reference numeral 3.1 and a passage 3.3 through the block 3.2. The crimp wings 2.2 and strain relief wings 2.3 are preferably present because they allow for a quick and efficient connection of the contact 1 to an electrical conductor and thus to a cable. Alternatives are also conceivable, so that crimp wings 2.2 and strain relief wings 2.3 are not necessarily required in this case either.They can therefore be replaced by other equivalent elements. Similar to DE 10 2015 201 381 A1, stops / detent elements or the like, not shown in detail, can also be provided for the overspring 3 on the base body 2.

[0015] Designing a contact or contact element in two parts is disadvantageous, particularly with regard to the parts to be assembled and the complexity of the manufacturing process, since two parts must be produced from a flat material in a forming operation, preferably a stamping and bending process, and then joined together after their manufacture. Reference is made to the embodiment shown in Figure 1 as an example.

[0016] The invention is therefore based on the objective of improving such a contact or such a contact element with regard to its manufacturing process and assembly in the contact chamber of the contact carrier.

[0017] This problem is solved by the features of claim 1.

[0018] The invention aims to design a contact (contact element, contact partner, contact system) in one piece and to manufacture it from a flat material using a forming process, in particular a stamping and bending process. The contact area consists of a single layer of the flat material.

[0019] According to the invention, a contact area and an adjoining block-like area for securing the contact in its contact chamber are formed by a folding process, thereby also forming the means for a primary locking mechanism and a secondary locking mechanism. Further according to the invention, the block-like area preferably has a rectangular cross-section. Other geometric cross-sectional shapes are also conceivable, such as a square, a circle, or the like. Accordingly, the cross-section of the contact chamber is adapted to the respective cross-section of the block used.

[0020] In the case of a rectangular cross-section, the contact can thus be inserted in two different positions relative to the contact carrier in its contact chamber. In the case of a square cross-section, four different positions are conceivable. Accordingly, the means for primary locking formed by the contact and the associated means in the contact chamber are also coordinated with each other.

[0021] If, in a further development of the invention, the means for the secondary locking are designed as the circumferential end region of the block-like area, they can come into contact with a corresponding contact surface of the contact chamber in a particularly advantageous manner, independent of the mounting position of the contact of the contact chamber.

[0022] The secondary locking mechanism is implemented on the contact carrier side. On the contact side, there is only an undercut and no active element. This undercut is created all the way around, which is the special feature of the novel design.

[0023] The novel design enables a so-called one-piece, polarization-free contact system, specifically a one-piece, polarization-free blade contact system. "Polarization-free" refers to the assembly process and not the electrical properties. This innovative design allows the contact to be mounted "upside down," thus preventing incorrect installation. The new design also allows for multiple manufacturing options. Furthermore, incorrect assembly is eliminated, unlike conventional one-piece (contact) systems where the transitions from the contact to the base body and from the base body to the crimp are such that the contact can only be mounted in one position.

[0024] A novel folding process enables the creation of a one-piece, code-free, and specifically foldable contact. This eliminates the need for a conventional spring mechanism or coding that dictates the assembly direction.

[0025] These folded contacts (contact systems) can be used as blade contacts in the automotive industry as well as for industrial applications. A further advantage is the ability to create chamber compatibility with third-party contact systems, including two-part contact systems (contacts).

[0026] A contact for a connector is proposed, comprising a contact area, a block-like area, and a connection area for contacting an electrical conductor. At least the contact area is formed from two layers of a planar material by means of a folding process. The area adjoining the contact area has a rectangular or circular cross-section. Primary locking means are integrated into / within the block-like area. The block-like area has a symmetrical stop facing the contact area. This stop is circumferential. A symmetrical plane is located on the rear side, facing the connection area. The symmetrical plane is circumferential. Preferably, the symmetrical plane is designed as an undercut. The contact itself consists of a planar, flexible material.

[0027] The invention is explained in more detail using an exemplary embodiment with drawings.

[0028] Figure 1 shows a two-part contact or a two-part contact element according to an in-house embodiment.

[0029] Figure 2: a one-piece contact or contact element according to an internal company design,

[0030] Figure 3: different views of a one-piece contact according to the invention,

[0031] Figure 4: a representation of the contact according to the invention in its unfolded state,

[0032] Figure 5: a representation of the contact according to the invention in the folded state,

[0033] Figure 6: the one-piece contact according to the invention in perspective view,

[0034] Figure 7: the contact according to the state of the art in perspective representation.

[0035] Figure 3 shows a one-piece contact 10 according to the invention in different representations.

[0036] The contact 10 essentially has a contact area 11, an adjoining, approximately transverse rectangular area 12, and a connection area 13. A transverse narrow area 14 serves only for handling and is usually cut off later after the contact 10 is completed.

[0037] Reference numerals 12.1 and 12.2 designate elements or means of a primary locking mechanism P on block 12. Block 12 has a symmetrical stop or stop surface 15 facing the contact area 11. Towards the rear, facing the connection area 13, there is a symmetrical plane 16 for a secondary locking mechanism S (not shown in detail). According to the invention, this symmetrical plane 16 is preferably circumferential and also preferably designed as an undercut.

[0038] Figure 4 shows the contours of a planar material for producing the contact 10 or contact element 10 before the folding process. Pointing upwards, a rectangular area 11 is shown, for example, which is folded around its longitudinal axis L to form the preferably elongated, narrow contact area 11 of the contact 10 (for example, a blade contact). Thus, two areas of the planar material lie one above the other and, in particular, directly adjacent to each other.

[0039] From the approximately transverse rectangular area 12 extending downwards, the block-like area 12 of the contact 10 is formed after the folding process. Further downwards, a connection area 13 adjoins, which, after forming, initially constitutes an open crimp area 13. By means of the formed crimp area 13, that is, its open crimp wings 13.1 and 13.2, the electrical conductor, for example of a cable (not shown in detail), is electrically contacted and fixed to the contact 10 in a manner known per se. The narrow, transverse area 14 of the flat material at the very bottom serves only for handling and can be cut off later after the contact 10 is completed. Strain relief wings are designated by the reference numeral 17.

[0040] In the illustration according to Figure 4 (maintaining the contours as shown in the left-hand illustration, Figure 3), the contact 10 is shown after the folding process. It can be seen that the front contact area 11 of the contact 10 is flat, specifically in the form of a blade, to which, when viewed from Figures 3 and 4, the block-like area 12 adjoins below. Two tabs 12.1, 12.2 for the primary locking mechanism P project diametrically opposite from this block-like area 12. The downward-pointing circumferential end area 16 of the block 12 serves to engage in the contact chamber (not shown in detail) and thus provides a secondary locking mechanism S. It is also shown that the connection area 13 is initially open, as no end of the electrical conductor has yet been inserted there.

[0041] The geometry of the planar material and the geometry of the contact 10 resulting from the forming process, which is preferably carried out around the longitudinal axis L of the contact 10, shown in Figures 3 and 4, are exemplary and can be changed and adapted to the intended use depending on the installation space, material, function of the contact (such as signal transmission or energy transmission) and the like.

[0042] The essential differences between the one-piece contact 5 (contact system) according to the prior art and the embodiment of the contact 10 according to the invention are illustrated in more detail in Figure 6 and Figure 7, which is realized by means of the folding process according to the invention, and are thus compared.

[0043] The one-piece contact system 10 according to the invention (Figure 7) has a transition area 18 from the contact body to the crimp area 13. A circumferential locking mechanism for the secondary locking S is possible. The transition area from the contact body to the contact 10 (blade) also creates a circumferential stop 15 (a circumferential stop surface) for the primary locking P.

[0044] According to the state of the art (Figure 6), a circumferential locking mechanism for secondary locking is not feasible due to the transition area between the contact body and the crimp area 5.2. Block 6 requires a so-called coding geometry for assembly. Furthermore, due to the transition area between the contact body and contact 5.4, a circumferential stop or stop surface for primary locking is not possible.

[0045] A contact 10 for a connector is proposed, wherein the contact 10 has a contact area 11, a block-like area 12, and a connection area 13 for contacting an electrical conductor. At least the contact area 11 is formed from two layers of a planar material by means of a folding process. The area 12 adjoining the contact area 11 has a rectangular or circular cross-section. Primary locking means 12.1, 12.2 are integrated on or in the block-like area 12. The block-like area 12 has a symmetrical stop 15 facing the contact area 11. This stop 15 is circumferential. A symmetrical plane 16 is located on the rear side, facing the connection area 13. The symmetrical plane 16 is circumferential. Preferably, the symmetrical plane 16 is designed as an undercut.The contact 10 itself consists of a flat, deformable, in particular bendable material.

[0046] Reference symbol list:

[0047] 1 contact, 2-part contact system

[0048] 2 contact bodies, base body

[0049] 2.1 Contact, contact body

[0050] 2.2 Crimp wings

[0051] 2.3 Strain relief wing

[0052] 3 overspring

[0053] 3.1 Primary locking element, means

[0054] 3.2 Block

[0055] 3.3 Implementation

[0056] 4 Contact area

[0057] 5-contact, one-piece contact system

[0058] 5.1 Transition area

[0059] 5.2 Crimping wings

[0060] 5.3 Strain relief wing

[0061] 5.4 Contact, contact body

[0062] 6 Block

[0063] 6.1 Primary locking element

[0064] 7 stops

[0065] Level 8

[0066] 10 contacts, one-piece contact system

[0067] 11 Contact area

[0068] 12 Block-like area, block

[0069] 12.1 Primary locking device

[0070] 12.2 Primary locking device

[0071] 13 Connection area, crimp area

[0072] 13.1 Crimp wings

[0073] 13.2 Crimp wings

[0074] 14 narrow area 15 stop, stop surface, all around

[0075] 16 End area, circumferential

[0076] 17 strain relief wings

[0077] P Primary locking

[0078] S Secondary locking mechanism

Claims

Patent claims 1. Contact for a connector, wherein the contact has a contact area, a block-like area and a connection area for contacting an electrical conductor, characterized in that at least the contact area (11) is formed from two layers of a planar material by means of a folding process.

2. Contact according to claim 1, characterized in that the area (12) adjoining the contact area (11) has a rectangular or circular cross-section.

3. Contact according to claim 1 or 2, characterized in that primary locking means (12.1 , 12.2) are integrated into the block-like area (12).

4. Contact according to one of claims 1 to 3, characterized in that the block-like area (12) has a symmetrical stop (15) pointing towards the contact area (11).

5. Contact according to claim 4, characterized in that the stop (15) is circumferential.

6. Contact according to one of claims 1 to 5, characterized in that a symmetrical plane (16) is located towards the rear, pointing towards the connection area (13).

7. Contact according to claim 6, characterized in that the symmetrical plane (16) is executed circumferentially.

8. Contact according to claim 6 or 7, characterized in that the symmetrical plane (16) is designed as an undercut.

9. Contact according to one of claims 1 to 8, characterized in that the contact (10) consists of a planar, deformable or bendable material.

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