Contact element, plug connector having a contact element, plug connector assembly having a plug connector, and electrical device having a plug connector assembly

Abstract

The invention relates to a contact element (1) for a plug connector (100), the contact element (1) being configured to be mounted, in particular detachably, on a busbar (301) of a component (300), in particular a component of a vehicle, and to be plugged together with a mating contact element (201) of a mating plug connector (200) in a plug-in direction (Z), the contact element (1) having: --a contact-making portion (2), configured to make contact with the mating contact element (201), at a first end (3); -- a mounting portion (4), configured for mounting on the busbar (301), at a second end (5); -- in particular a fastening portion (6), configured for coupling, in particular detachably, to a plug connector housing (101) of the plug connector (100); and the contact element (1) being produced as an extruded part, in particular in one piece.

Description

[0001] R. 416213

[0002] - 1 -

[0003] Description

[0004] title

[0005] Contact element, connector with a contact element, connector assembly with a connector and electrical device with a connector assembly

[0006] Field of invention

[0007] The invention relates to a contact element, a connector with a contact element, a connector arrangement with a connector and an electrical device with a connector arrangement.

[0008] State of the art

[0009] Electrical connectors typically consist of a (often insulating) connector housing and at least one contact element. These contact elements are manufactured as stamped and bent parts from readily available, cost-effective standard materials from various manufacturers (sheets of different materials, properties, and / or thicknesses) and are available in many variations, e.g., as socket contacts, contact blades, fork contacts, etc. Depending on the application, desired properties, and dimensions, a suitable sheet can easily be purchased "off the shelf" and formed into the desired contact element through the stamping and bending process. A wide variety of sheets or rolled sheets with different wall thicknesses, materials, and surface properties (e.g., different coatings, roughness, etc.) are advantageously available for this purpose.Furthermore, such stamped and bent parts can be manufactured with known machines at a high throughput rate, requiring only the provision of the sheet metal or rolled sheet metal. In the area of ​​connectors, especially connectors for vehicles, e.g., electric cars, two-wheelers, three-wheelers, quads, trucks, commercial vehicles, boats, airplanes, helicopters, drones, etc., for the transmission of high power (e.g., at least 1 kW), see R. 416213.

[0010] - 2 - or for high currents (e.g. at least 1 A or at least 10 A) or for use at high voltages (e.g. at least 40 V or at least 100 V), contact elements with a cross-section of, for example, at least 10 mm² are generally used. 2Used to achieve sufficient current-carrying capacity, such connectors with this type of contact element are, for example, plugged together with mating connectors, which may, for example, have a complementary contact element, particularly during vehicle assembly. Such a plug connection or connector assembly should also function without interruption during operation, for example, under high temperature fluctuations, vibrations, and mechanical shock loads. Furthermore, it should be easy to connect (plug in) and disconnect (unplug) with minimal (manual) force.

[0011] German patent DE 10 2008 045 810 A1 discloses an electrical fork contact, suitable for use in automotive applications, for a stamped grid of a power distribution unit for high electrical currents. The fork contact is manufactured as a stamped and bent part from a stamped sheet.

[0012] From DE 10 2021 108 916 A1, a contact arrangement for transmitting an electrical voltage and a connection module with a contact arrangement are known. The contact arrangement is suitable, for example, for use in automotive applications, e.g., for an inverter that can be operated with voltages of 48 V or 60 V or higher (e.g., in so-called high-voltage applications). The contact arrangement has at least one fork contact with a first U-shaped, flat end and a second end opposite the first end with a cylindrical contact surface. The fork contact is arranged with its first end outside and its second end inside the housing. The fork contact is designed as a one-piece stamped and bent part, or the fork-shaped part, designed as a stamped sheet metal part, is connected to the cylindrical part, e.g., by a welding or soldering process.

[0013] From EP 4 089 864 A1, a contact device for a double busbar is known, wherein the double busbar has two busbars stacked on top of each other, wherein the contact device has an even number of connectors per busbar arranged symmetrically to an axis of symmetry of the contact device, wherein the connectors R. 416213

[0014] - 3 - both busbars are aligned in a common connector plane. Flat contacts, designed as stamped and bent parts, are arranged between the busbars of the double busbar and the connectors.

[0015] Disclosure of the invention

[0016] The invention is based on the understanding that manufacturing a contact element (particularly for use in or on vehicles) as a stamped and bent part for a connector, especially for a connector for transmitting high power, high currents, and / or for use at high voltages, can be relatively expensive using conventional processes. Manufacturing a contact element as a stamped and bent part requires a progressive die, in which, among other things, the stamping, embossing, bending, and clinching steps must be performed. Changes to the geometry of the stamped and bent part necessitate costly modifications to the die.Furthermore, the invention is based on the understanding that while the sheet metal used can be obtained inexpensively as standard material, a significant proportion of the supplied sheet metal is generated as waste during the production of such contact elements. This is not particularly sustainable, as this waste must be remelted using a high energy expenditure or disposed of. The invention is further based on the understanding that when attaching such contact elements to busbars of a component (e.g., an inverter, a battery, an electric machine, etc.), particularly a vehicle component, nuts for screwing and / or reinforcing parts must be attached to the finished stamped and bent contact elements (e.g., due to the relatively thin sheet metal). Sufficient installation space is required for attaching (e.g., pressing in) these fastening elements.On the one hand, providing sufficient assembly space is necessary, and on the other hand, adapting the fastening position (the location of the reinforcing element or the nut) is very complex, since the fastening process of these elements also takes place in the progressive die. Thus, such contacts are relatively large, and adapting the fastening position, e.g., at the customer's request, is time-consuming and involves high costs for a new die. Furthermore, the invention is based on the understanding that such contact elements offer only limited design possibilities for, e.g., stability optimization or heat dissipation during operation (high currents), or require costly subsequent processes (e.g., incorporating R. 416213).

[0017] - 4 - of beads or multiple bends or the milling of profiles for fastening the contact element in the connector housing), since the contact element is made from a sheet of metal with a defined thickness. Furthermore, the invention is based on the knowledge that, due to the elastic properties of these sheets, punching and bending such sheets only allows relatively large tolerances in the spacing and dimensions of the contact elements (e.g., length, distance between two contact blades in fork contacts, angles in bent sections, e.g., mounting sections relative to contacting sections, etc.), since the sections bent relative to each other are at least partially resiliently connected. Furthermore, the invention is based on the knowledge that, in order to achieve a high current-carrying capacity, e.g.,Relatively thick sheets of metal must be used, which are difficult to punch and bend (expensive and large tools, rapid tool wear), so that different sub-segments are better manufactured separately and then, for example, welded or soldered together, or that a large number of bending and / or embossing operations are required to form a contact element with a correspondingly thick wall for high current carrying capacity from an initially thin sheet of metal.

[0018] Therefore, there may be a need to provide a contact element, particularly for a connector, especially for vehicles, for transmitting high electrical power, which is cost-effective, easy to manufacture with low material waste, which is robustly designed, which is preferably adaptable to a mounting position on a busbar with minimal effort, which is sustainable to manufacture, which allows the production of complex geometries with low tolerances, which has a high current-carrying capacity, which is easy to dissipate heat, and which is also easy to attach to or in the connector housing and / or, for example, to a busbar.

[0019] Advantages of the invention

[0020] This need can be met by the subject matter of the present invention according to the independent claims. Advantageous embodiments of the present invention are described in the dependent claims.

[0021] According to a first aspect of the invention, a contact element for a connector, particularly for use on or in vehicles, is proposed. R. 416213

[0022] - 5 -

[0023] The contact element is designed for mounting on a component's busbar and for mating along a specific direction with a mating contact element of a connector. The contact element has a contact section at its first end, configured for contacting the mating contact element. The contact element also has a mounting section at its second end, configured for mounting on the busbar. The contact element is manufactured as an extruded part.

[0024] This results in a surprisingly advantageous way: a contact element that is easy, cost-effective, quick to produce with minimal effort and material waste, and can be manufactured in a particularly compact form. Furthermore, a particularly simple and cost-effective tooling concept with a small footprint can be provided. Additionally, the production of the final contact element can be carried out with great flexibility: for example, directly in succession or distributed across different production locations or points within a single manufacturing site. For instance, extrusion can take place at one location (e.g., in a location with low energy costs). Further processing, such as cutting the strand to length or dividing it into individual contact elements, can then take place at another location, which could be many kilometers away.It goes without saying that a different layout is also possible, or that all manufacturing steps can be carried out at a single location. This allows for a more flexible arrangement and distribution of the individual tools used in manufacturing compared to a progressive die in a stamping and bending process. Furthermore, it is advantageous to achieve particularly high stability (and / or high rigidity) for the contact element, especially in the contact area or section, as well as low tolerances and low manufacturing tolerances, and simultaneously good elasticity and flexibility in the connection areas. Another advantage is that the geometry of the contact element can be easily selected and manufactured according to requirements without numerous processing steps – the geometry can thus be adapted to mechanical, electrical, thermal, etc., requirements with a simple manufacturing process (e.g.,...).Provision, introduction and adaptation of mounting options or mounting locations on the contact element for mounting on the busbar; R. 416213.

[0025] - 6 - e.g., mechanical stability; e.g., simple and / or secure coupling with the connector or connector housing; possibly a certain degree of flexibility, e.g., in the area around the mounting section, to enable trouble-free connection to, e.g., a rigid and inflexible busbar; e.g., current-carrying capacity; e.g., heat dissipation; etc.). Furthermore, it is advantageous – in contrast to the stamping-bending process – to prevent significant changes in the crystal structure of the contact element at sharply bent sections and thus avoid inhomogeneities in mechanical and electrical performance.

[0026] Furthermore, this allows for the provision of a contact element made from materials that cannot be readily cold-formed (e.g., due to brittleness) and / or where a maximum forming angle must not be exceeded due to the material properties and / or sheet thickness of a stamped and bent part, but which is nevertheless below the forming angle required for the shaping process. It is understood that the advantages also apply to contact elements with thin walls, e.g., less than 2 mm. Finally, with an extruded contact element, especially a one-piece contact element, significantly or extremely different thicknesses and / or cross-sections can be advantageously provided, and / or (especially large) thickness variations can be advantageously realized, which is not possible with a stamped and bent part.This is only possible through multiple bends, especially around 180° angles, since the punching and bending processes are carried out on a rolled sheet of constant thickness.

[0027] It may be provided, for example, that the contact element can be detachably mounted on the busbar, or is already mounted, e.g., detachable without damage.

[0028] The component could, for example, be a component of a vehicle.

[0029] It may be provided, for example, that the contact element has a fastening section, wherein the fastening section is designed for coupling, in particular detachable coupling, with a connector housing of the connector.

[0030] The contact element can, for example, be manufactured as a single piece using an extrusion process, or be integrally manufactured or integrally formed. In other words, no further elements are necessary that are connected to the extruded part and possibly R. 416213.

[0031] - 7 - The cut-to-length raw contact element must be connected or coupled to obtain or form the functional or final contact element (as it exists, for example, in the final state of the connector). For example, if the contact element is a single piece, it is not composed of a previously separate contacting section and a previously separate assembly section. It is understood that cutting to length and / or drilling or creating an opening does not preclude the contact element from being a single piece. Similarly, surface treatment, such as applying a coating, electroplating, etc., does not preclude it from being a single piece.

[0032] The contact element can, for example, be made of a material, or consist predominantly of such a material, that conducts electricity well, in particular a metal. It can, for example, consist (in particular predominantly) of copper, aluminum, or silver.

[0033] The contact element can be connected to the busbar in the assembly section, or attached to it, particularly in a detachable manner. The contact element can be attached to the busbar by means of a screw connection, a rivet connection, or a clip connection; other connection options (e.g., bayonet connection, clinching, welding, soldering, gluing, etc.) are also conceivable.

[0034] The contact element can be mounted or arranged in or on the connector, particularly in or on the connector housing. It can be molded, snapped, pressed ("stitched"), or clamped into the connector or its housing. This fastening can take place, for example, in the contact element's mounting area.

[0035] The contact element can be, for example, part or element of a connector designed as a so-called pin header, or part or element of a connector designed as a knife strip.

[0036] The busbar can also be called a contact rail or "busbar". The busbar can be, for example, a part or element of a component (e.g., R. 416213).

[0037] - 8 - of an inverter, etc.). The busbar cannot, for example, be part of the connector.

[0038] A current-carrying element, e.g., a so-called FPC (flexible printed circuit), can also be understood as a busbar in the context of this application. For the sake of readability, the term "busbar" is also used for such elements.

[0039] The term "zeigen" is used synonymously with the term "fassen" unless otherwise stated.

[0040] A Cartesian coordinate system may be used. This could, for example, be formed from

[0041] • the insertion direction or Z-direction, which can also be a longitudinal direction or longitudinal extension direction (but does not have to be),

[0042] • the X-direction perpendicular to it, which can be (but does not have to be) a contact direction between the contact element and the counter-contact element and

[0043] • a transverse direction or Y-direction perpendicular to these two directions, which may (but does not have to) correspond to an extrusion direction in the manufacture of the contact element.

[0044] The contact element can, for example, have an elongated shape. It can be provided, for example, that the mounting section and the contacting section extend along a longitudinal direction of the contact element, in particular along the insertion direction. It can be provided, for example, that the optional fastening section is arranged between the contacting section and the fastening section. It can be provided, for example, that the optional fastening section lies in line with the mounting section and the contacting section.

[0045] The contact element can, for example, have an extension length (from the mounting section to the contacting section) in the range of 10mm to 100mm, preferably from 20mm to 80mm, particularly preferably from 20mm to 50mm, e.g. 30mm or 35mm or 40mm.

[0046] It can, for example, have a width (e.g., measured parallel to a contact direction or the X-direction) in the range of 5 mm to 40 mm, preferably from 7 mm to R. 416213

[0047] - 9 -

[0048] 35mm, preferably from 9mm to 30mm. For example, it can have a width of 10mm, 12mm, or 14mm.

[0049] It can, for example, have a depth (e.g., measured perpendicular to the contact direction and parallel to the contact plane) in the range of 7mm to 50mm, preferably 9mm to 40mm, particularly preferably 10mm to 30mm, e.g., 12mm or 15mm or 18mm.

[0050] For example, it is advantageous to achieve a low tolerance of dimensions, in particular of the gap between contact blades (in fork contacts), which is in the range of + / -0.02 mm to + / -0.08 mm, preferably from + / -0.03 mm to + / - 0.07 mm. For example, a tolerance of + / - 0.06 mm, + / - 0.05 mm, or + / - 0.04 mm can be achieved.

[0051] The contact element, especially in the contact area (e.g., on contact blades), can have a first wall thickness (described in more detail below) ranging from 1.8 mm to 2.5 mm (e.g., for conductor cross-sections of 25 mm²). 2 up to 50mm 2 ) or which is up to 5mm (e.g. for conductor cross-sections of 150mm) 2It is understood that such wall thicknesses, when manufactured as a stamped and bent part, necessitate large bending radii (bend radii should generally be chosen that do not (significantly) fall below the material thickness) and result in considerable wear on the stamping tools. Furthermore, enormous forces are required, which greatly increases the size and cost of such progressive dies for stamped and bent parts. It is also understood that the material thickness, particularly in the contact section, can depend on the depth of the contact section and the required current-carrying capacity. It is further understood that the proposed contact element can certainly have even greater wall thicknesses in other sections, thus potentially increasing mechanical and thermal stability (e.g., selectively and at specific points).

[0052] Furthermore, the proposed contact element can be advantageously designed symmetrically in a simple manner (e.g., mirror-symmetrical about a plane that runs parallel to or perpendicular to a contact plane, etc.; or rotationally symmetrical with respect to a rotation of 90° or 180° about a longitudinal axis; or point-symmetrical with respect to a longitudinal axis). This is because, compared to a stamped and bent part, for example, no asymmetrically designed stiffening tabs are required. R. 416213

[0053] - 10 - or clinch structures (tongue and groove structures) are required to provide sufficient mechanical stability.

[0054] Furthermore, it is advantageous that the connection surface between the contact element and the busbar can be easily designed with virtually any geometry (e.g., a wide base for connection and a slender and / or tapered section projecting towards the contact area). This makes it possible to adapt the connection surface to the required current-carrying capacity (e.g., a cross-sectional area that is at least equal to the cross-sectional area of ​​the conductor connected to the busbar or that is at least equal to the cross-sectional area of ​​the busbar) while simultaneously requiring only a small installation volume (especially in the mounting section).

[0055] Furthermore, it is particularly advantageous that a press-fit structure, e.g. a profile, can be arranged in the fastening area very easily, especially over a large area along the extrusion direction of the contact element (and not just on a narrow side as with a stamped and bent part).

[0056] Furthermore, it is advantageous to forgo bulky and difficult-to-manufacture stiffening structures (e.g., bent tabs that require complex clinching to each other or to other parts of the contact element (tongue-and-groove system)). Instead, the contact element can be directly dimensioned to provide sufficient stability or at least a reinforcing element (e.g., at least one brace) can be incorporated at suitable locations. These structures can also be located inside the contact element, so that, for example, a mounting section with a profile for press-fit installation can be formed directly below the contacting section. With stamped and bent parts, press-fitting in a reinforced area with clinched tabs would carry the risk of warping the contact element and making it impossible to maintain very tight tolerances.A snap-fit ​​assembly, possible with stamped and bent parts, is susceptible to vibration (due to the necessary clearance) and carries the risk of frictional wear at the contact point with the mating contact element. A contact element designed as an extruded part enables high stability and press-fit assembly with tight tolerances and high vibration resistance or low frictional wear. R. 416213.

[0057] - 11 -

[0058] Furthermore, compared to a stamped and bent part, it is advantageous to prevent stresses from being frozen into the bends during the cold forming process. These stresses can cause the contact element to "work" during temperature changes (e.g., due to current), particularly at the bends, and thus the position of the contact element relative to the mating contact element can change, leading to frictional wear. The extruded contact element advantageously results in a longer service life and less wear.

[0059] Further training aims to ensure that the contact element is designed to transmit high power. This can significantly reduce manufacturing costs and simplify the fulfillment of geometric requirements for such contact elements. Extrusion is particularly effective at achieving high wall thicknesses, large offset angles, and significant thickness variations between individual sections.

[0060] In the context of the application, high performance can be understood to mean, for example, a power output of at least 1 kW, at least 10 kW, or at least 50 kW.

[0061] Alternatively or additionally, the contact element is designed to be installed or mounted in a high-voltage (HV) connector, or to operate at high voltages. This significantly reduces manufacturing costs and simplifies the fulfillment of geometric requirements for such contact elements. High wall thicknesses, large offset angles, and significant thickness variations between individual sections are particularly easy to achieve through extrusion.

[0062] In the context of the application, the term "high voltage" can be understood to mean, for example, a voltage of at least 40V, at least 60V, at least 100V, or at least 220V.

[0063] Alternatively or additionally, the component is designed as a high-voltage component (HV component), in particular selected from the group consisting of: a voltage converter, in particular an inverter; an energy storage device, in particular a battery; an electric machine. R. 416213

[0064] - 12 -

[0065] This advantageously ensures that the contact element is designed to be particularly safe for the operation of such a component.

[0066] The component or HV component can in particular be a component of a vehicle, e.g. a land-based vehicle (e.g. cars, two-wheelers, three-wheelers, quads, etc.; trucks, agricultural vehicles, construction vehicles, commercial vehicles) that is at least partially electrically powered or driven, and / or a water-based vehicle (e.g. boats, floating or diving vehicles) and / or an aircraft (e.g. airplanes, helicopters, drones, zeppelins, etc.) and / or a spacecraft.

[0067] In a further development, it is provided that the contact element is selected from the group: a knife contact, in particular a flat knife contact; a fork contact with at least two contact knives spaced apart from each other, in particular running parallel to each other.

[0068] Designing the contact as a knife contact, particularly as a flat knife contact, allows for a particularly simple manufacturing process and a particularly large contact area and / or a particularly high current-carrying capacity and / or a particularly low contact resistance to the mating contact element. A transition from the contact area to the mounting area or fastening area can be formed in one piece, especially if the mounting area and / or fastening area has a shape that differs from the knife or flat knife geometry.

[0069] A flat knife contact can, for example, have an aspect ratio of a wall thickness in the contacting area and a length and / or a width of the contact surface in a ratio of at least 1 :1 .5 or at least 1 :2 or at least 1 :3 or at least 1 :5.

[0070] The design as a fork contact with at least two spaced-apart, and in particular parallel, contact blades advantageously results in a particularly large contact area for contact with a mating contact element and particularly high robustness with regard to uninterrupted contact against vibrations and shocks. Furthermore, such a designed extruded contact element advantageously results in the following: R. 416213

[0071] - 13 -

[0072] The distance tolerance between adjacent contact blades can be kept particularly small. Furthermore, this allows for particularly simple manufacturing of the contact element. A transition from the contact area to the mounting area or fastening area can be formed in one piece, especially if the mounting area and / or the fastening area has a shape that differs from the geometry of the forked contact area.

[0073] In a further training course, it is stipulated that (at least) one opening for inserting or passing through a fastening element is provided in the assembly section.

[0074] This allows for a particularly simple coupling or connection to the busbar. Furthermore, the contact element can be made especially small. This coupling or mounting option (the opening) can also be easily and variably positioned within the assembly section (e.g., to accommodate different customer requirements). The need for a fastening element, such as a separate nut, within the assembly section is advantageously eliminated. Similarly, the costly and time-consuming redesign of a progressive die (stamping and bending) when the mounting position changes is also eliminated.

[0075] The opening can be designed, for example, as a through-hole. This makes it particularly easy to connect to the busbar, for example, by means of a screw connection (e.g., inserting a screw and securing it with a nut), a press-fit connection, a rivet connection, etc.

[0076] The opening can be designed, for example, as a blind hole. This makes it particularly easy to connect to the busbar, for example, by means of a press-fit connection, a screw connection (e.g., by screwing in a screw), a rivet connection (e.g., with a blind rivet, etc.), etc.

[0077] The opening can, for example, have a smooth inner wall. Alternatively or additionally (e.g., in sections), it can have a thread. When a screw is inserted into the opening, this screw can, in principle, also cut a thread into an initially smooth inner wall of the opening. R. 416213

[0078] - 14 -

[0079] It is understood that exactly one opening may be provided in the assembly section for inserting or passing through a fastener. However, several such openings may also be provided in the assembly section. This can allow for improved flexibility during assembly. The opening can, for example, be circular. Alternatively, it can be elongated. In the latter case, flexibility during assembly can be increased, particularly with regard to manufacturing and / or assembly tolerances.

[0080] In a further training course, it is stipulated that the opening (or a plurality of such openings) runs parallel to the insertion direction.

[0081] This makes it advantageous to provide a particularly small contact element, especially when viewed parallel to the insertion direction.

[0082] In a further training course, it is stipulated that the opening (or a plurality of such openings) runs parallel to the extrusion direction.

[0083] This allows the contact element to be manufactured particularly easily. For example, it can be advantageous to provide the opening during extrusion, so that it does not have to be created by an additional opening-manufacturing step (e.g., a drilling step, milling step, EDM step, laser melting step, etc.) after extrusion.

[0084] This advantageously allows for a particularly simple, fast and cost-effective production of the contact element without a step of creating the opening after completion of the extrusion step.

[0085] Alternatively, it is provided that the opening (or a plurality of such openings) runs perpendicular to the insertion direction.

[0086] For example, it may be provided that the opening runs parallel to a contact plane of the contacting section.

[0087] This allows for a particularly stable mounting on the busbar. An example is the contact element along a long length with R. 416213.

[0088] - 15 - connectable to the busbar. In particular, if the opening is designed as a through-hole, the opening can extend along the entire length of the contact plane, thus ensuring a uniform force distribution on the contact element, or be designed to be particularly flexible with regard to assembly tolerances.

[0089] Alternatively, it is provided that the opening runs perpendicular to the insertion direction.

[0090] It may be provided, for example, that the opening (or a plurality of such openings) runs perpendicular to the contact plane of the contacting section.

[0091] This allows for the advantageous use of a particularly short fastening element (e.g. a screw and / or a rivet) for mounting on the busbar.

[0092] If multiple openings are provided, these openings can be oriented in different directions, for example, in the directions described above. This allows for flexible connection to different busbars or connection points.

[0093] In a training course, the assembly section and the fastening section are designed to overlap.

[0094] This advantageously allows for a particularly short overall length of the contact element.

[0095] The overlap can occur, for example, when viewed in a direction perpendicular to the mounting direction of the contact element in the connector housing. In other words, if the contact element is viewed along the mounting direction, the mounting section and the fastening section are at least partially at the same height.

[0096] The overlap can occur, for example, in a direction perpendicular to the extrusion direction. In other words, if one considers the contact element along the extrusion direction, the mounting section and the fastening section are at least partially at the same height. R. 416213

[0097] - 16 -

[0098] In a further development, it is provided that the contact element in the contacting section has a first wall thickness, wherein the contact element in the assembly section has a second wall thickness, in particular wherein the contact element in the fastening section has a third wall thickness, wherein the first wall thickness differs from the second wall thickness and / or in particular from the third wall thickness.

[0099] This allows for a simple, cost-effective, and material-saving approach to addressing the different functions and / or requirements (e.g., mechanical, electrical, thermal, etc.) of the various areas or sections of the contact element, without the disadvantages of a specific wall thickness in an area where that thickness is not needed. Extrusion of the contact element enables the straightforward production of these different wall thicknesses (and even large thickness variations over short distances) advantageously in a single operation, eliminating the need for further steps such as multiple bending, pressing, milling, etc. Furthermore, this method advantageously avoids crystalline deformation of the starting material (e.g., a sheet metal part in a stamped and bent component) caused by sharp bends (e.g., 180°) or plastic deformation.

[0100] The difference between the first wall thickness, the second wall thickness and / or the third wall thickness can be, for example, at least 10% or at least 25%.

[0101] In principle, the contact element can, for example, have cavities and / or bracing between different wall sections, e.g., between adjacent or opposing wall sections. Such geometric structures (cavities, bracing, etc.) can advantageously be designed very simply, quickly, and cost-effectively. They can, for example, be formed in one piece or integrally within or on the contact element. In other words, an element or support element (e.g., a brace) between two wall sections can be integrally formed with these wall sections. The contact element can thus be advantageously very lightweight, material-efficient, very stable, and designed with very tight tolerances (manufacturing tolerances, operational tolerances, etc., e.g., under strong vibrations and / or temperature fluctuations and / or mechanical pressure or tension). This is particularly relevant even for complex geometric structures, as described in R. 416213.

[0102] - 17 -

[0103] The manufacturing process generates very little material waste (especially compared to stamping, bending, or milling processes). Compared to 3D printing, it offers a significant time advantage for complex structures.

[0104] In a further training course, it is stipulated that a groove, in particular one opening outwards, is provided in the fastening section.

[0105] This can advantageously reduce the weight of the contact element. Furthermore, it can advantageously provide an undercut that allows the contact element to be mounted in or on the connector or connector housing using a snap-fit ​​structure of the connector or housing, e.g., a snap-fit ​​tab, a snap-fit ​​lance, etc. Particularly advantageously, the groove can be easily integrated directly into the contact element during extrusion. It is advantageously unnecessary to, for example, repeatedly reshape a sheet metal part to create the groove, nor is a subsequent forming process, such as milling, required. This enables simple, fast, and cost-effective production of this structure on the contact element.

[0106] There can be exactly one groove. However, there can also be multiple grooves.

[0107] Preferably, at least one groove runs parallel to the extrusion direction. This makes it advantageous for at least one groove to be manufactured or formed on the contact element particularly easily.

[0108] Alternatively or additionally, it is provided that a projection, especially one directed outwards, is provided in the fastening section.

[0109] This can advantageously provide an undercut that allows the contact element to be mounted in or on the connector or in or on the connector housing by means of a snap-fit ​​structure of the connector or connector housing, e.g., a snap-fit ​​lug, a snap-fit ​​lance, etc. Furthermore, this can advantageously cause the contact element to be clamped, pressed, or clawed in or on the connector or connector housing. For example, pressing or stitching the contact element can be advantageously enabled by this. The projection can be particularly advantageous in simple R. 416213.

[0110] - 18 -

[0111] The protrusion can be formed directly on the contact element during extrusion. Preferably, it has an interference fit with the mounting section. It is advantageously unnecessary to, for example, reshape a sheet (multiple times) to create the protrusion, nor is a subsequent forming process, such as milling, required. This enables simple, fast, and cost-effective production of this structure on the contact element.

[0112] There can be exactly one advantage. However, there can also be multiple advantages.

[0113] Preferably, the at least one projection runs parallel to the extrusion direction. This makes it advantageously easy to manufacture the at least one projection or to form it on the contact element.

[0114] Alternatively or additionally, it is provided that a profile is provided in the fastening section, in particular for locking and / or clawing and / or hooking with the connector housing, in particular a fir tree profile (especially with differently projecting protrusions) or a barbed profile.

[0115] This allows for a particularly secure and reliable mounting of the contact element in or on the connector or connector housing. In particular, the contact element can be mounted in or on the connector or connector housing by means of a press-fit or stitching process. The profile can be easily incorporated directly into or formed on the contact element during extrusion. The profile can have virtually unlimited shapes and can therefore be flexibly adapted to the respective application. It is advantageously unnecessary to, for example, repeatedly reshape a sheet metal part to create the profile, nor is a subsequent forming process, such as milling, required.It is also advantageous for the profile to be applied to a surface parallel to the contact surface and not merely to a stamped edge as with a stamped and bent part. This enables simple, fast, and cost-effective production of this structure, especially a large-area structure, on the contact element. R. 416213.

[0116] - 19 -

[0117] Preferably, at least one profile runs parallel to the extrusion direction. This makes it advantageous for at least one profile to be manufactured or formed on the contact element particularly easily.

[0118] For example, the connector housing may have a stepped (internal) contour, particularly if, for example, a fir-tree profile is provided in the mounting section. The stepped contour may be located, for example, in the area of ​​the connector housing where the contact element is positioned in the fully assembled state. It may, for example, be located in a contact chamber. At least one step may be provided, preferably a separate step for each differently projecting section of the fir-tree profile. The steps may, for example, be designed to be complementary to the projections of the fir-tree profile. This advantageously ensures that, when the contact element is pressed into the connector or the connector housing, each individual projection follows its own undamaged path (not damaged by another projection) within the contact chamber.Particularly in their final position, the protrusions are not guided by already scratched or worn mounting marks in the connector housing. Furthermore, it is advantageous that the protrusions are virtually melted into the wall, as the high frictional energy during pressing locally melts a corresponding area of ​​the connector housing, and this molten material then solidifies behind the protrusion(s) at the end of the pressing process.

[0119] In a further development, it is provided that at least one cooling fin is formed on the contact element, in particular on an outer side of the contact element.

[0120] This enables simple, fast, and cost-effective intrinsic heat dissipation from the contact element. Particularly advantageous is the ability to easily integrate at least one cooling fin directly into the contact element during extrusion or to form it on the contact element itself. The profile can have virtually unlimited shapes and can therefore be flexibly adapted to the respective application. It is advantageously unnecessary to, for example, repeatedly reshape a sheet metal part to create the profile, nor is a subsequent forming process, such as milling, required. Furthermore, the profile can advantageously be applied to a surface parallel to the contact surface. R. 416213

[0121] - 20 - not merely at a stamped edge as with a stamped and bent part. This enables simple, quick and cost-effective production of this heat dissipation structure, especially a large-area heat dissipation structure, on the contact element.

[0122] There can be exactly one cooling fin or exactly one cooling structure. However, there can also be multiple cooling fins, cooling structures, or heat dissipation structures.

[0123] Preferably, at least one cooling fin or cooling structure runs parallel to the extrusion direction. This allows the at least one cooling fin to be manufactured or formed on the contact element particularly easily.

[0124] In a further development, it is provided that at least one cooling fin is arranged in the contacting section, in particular on a side that is facing away from the side contacted by the mating contact element.

[0125] This allows the heat dissipation to advantageously take place directly at the point or in an area where a particularly large amount of heat can be generated as a result of the contact resistance between the contact element and the counter-contact element (in the area of ​​the contact point or contact points).

[0126] Alternatively or additionally, it is provided that at least one cooling fin is arranged in the mounting section.

[0127] This advantageously ensures that at least one cooling fin does not cause any geometric widening in the contact area or the mounting area. Furthermore, it can also be advantageously used for fastening in or to the connector or connector housing. For example, it can form an undercut for a locking lug or hook of the connector.

[0128] Alternatively or additionally, it is provided that at least one cooling fin is arranged in the assembly section, in particular on an outer surface of the assembly section. R. 416213

[0129] - 21 -

[0130] This advantageously enables particularly good heat dissipation, especially when the busbar is part of an actively cooled component (e.g., a component with air and / or liquid cooling). Furthermore, it is advantageous that the heat from the connector or connector assembly is transferred to another component, and the connector and / or mating connector can be manufactured or designed to be particularly compact.

[0131] In a further training course, it is stipulated that the contact section has different wall thicknesses.

[0132] This allows the contact section to be advantageously designed with simple means and cost-effective manufacturing (no (multiple) bending, milling, etc. necessary), making it particularly flexible, and additional functions can be easily assigned to it besides its contacting function. In other words, it is advantageous to achieve the integration of several functions within the contact section.

[0133] For example, it may be provided that a contact section groove and / or a contact section projection is provided in the contact section.

[0134] This makes it advantageous to arrange or attach further elements to the contact element particularly easily, e.g. a touch protection element and / or a sensor and / or a control element, e.g. a temperature sensor or a PTC element or a PTC resistor (Positive Temperature Coefficient element) or the like.

[0135] Alternatively or additionally, it may be provided, for example, that such a contact section groove and / or such a contact section projection is set up as a coding means for the mating contact element and / or as a stop (positioning aid) for the mating contact element and / or as a receptacle for a sensor or a control element.

[0136] As a coding element, it can be ensured, for example, that only a suitable, e.g., complementary, and / or correctly aligned mating contact element can be connected to the contact element. This prevents incorrect connections. R. 416213

[0137] - 22 - advantageously prevented. Preferably, the contact section groove and / or the contact section projection can be provided in a plugging direction between the contact element and the mating contact element that extends substantially parallel to the extrusion direction.

[0138] As a stop, such a structure can, for example, ensure that a mating contact element does not exceed a defined maximum position relative to the contact element. This can advantageously achieve the best possible contact and / or prevent damage during the insertion process. Such a stop can be particularly helpful, for example, if the insertion direction is approximately perpendicular to the extrusion direction. It can be specifically designed so that a cavity runs beneath the stop, into which the mating contact element could slip without the stop. Furthermore, it can be designed, for example, so that the stop does not completely close off this cavity. In other words, the stop does not form a solid base.

[0139] A recess for a sensor and / or a control element can be designed, for example, as a groove, such as the groove of the contact section. It can be located, for example, near the contact point between the contact element and the mating contact element. It can (but does not have to) be located on the side of the contact section wall facing away from the contact surface. A temperature sensor, for example, can be used as the sensor. This can be helpful for detecting overheating of the contact element or the connector in a timely manner, for example, as a result of a (prolonged) high current. A PCT element or similar device can be used as the control element, which can regulate the current flow through the contact element directly or indirectly (e.g., by means of a control unit). In this way, such a sensor or control element can be positioned particularly close to the actual contact point and in a particularly space-saving manner.

[0140] It may be provided, for example, that a section with a reduced wall thickness forms an arrangement section for arranging a lamellar element in the contacting section. Such a lamellar element may, for example, have a single (in particular elastic and / or elastically reversible) contact lamella or a plurality of (in particular elastic and / or elastically reversible) contact lamellae that provide electrical contact to the mating contact element R. 416213.

[0141] - 23 - effect. The lamellar element can, for example, be placed on or in the arrangement section. It can, for example, be attached to the contact element by positive locking, friction locking, or material locking. For example, it can be bent around a wall of the contact element and / or glued, welded (e.g., laser-welded), or soldered to the contact element, although other fastening methods are also conceivable.

[0142] In a further development, it is provided that the contact element has a compensating section, wherein in the compensating section a wall of the contact element, in particular viewed along the insertion direction, has at least one left-curved section and / or at least one right-curved section, in particular both at least one left-curved section and at least one right-curved section.

[0143] This advantageously simplifies the mounting of the contact element to the busbar, particularly with a very rigid busbar and / or a tolerance edge position. If the two mounting partners are not ideally aligned during mounting the contact element to the busbar, the compensating section provides a certain degree of elasticity or flexibility in the contact element. This prevents both unnecessarily high force requirements and plastic deformation of the contact element and / or busbar during installation. Simultaneously, the advantage of a very stable contact element with high current-carrying capacity and inherently thick walls can be maintained. In other words, geometric elasticity or shape elasticity is provided, particularly to facilitate the connection of the contact element to the busbar.Furthermore, the flexibility or elasticity provided by the compensating section can be advantageous in helping to at least partially compensate for thermal expansion of the busbar during operation, thus maintaining spatial stability at the contact point between the contact element and the mating contact element. In other words, if the busbar undergoes changes in length, width, and / or thickness due to energization and subsequent heating, the compensating section can prevent these changes from affecting the position of the contact point between the contact element and the mating contact element via the contact element connected to the busbar, or at least limit the extent of the change (see R. 416213).

[0144] - 24 - transferred to the contact point to a reduced extent. Wear at the contact point can therefore be reduced.

[0145] Furthermore, vibrations, such as those occurring on the busbar, can be advantageously dampened by the compensating section, thus preventing them from reaching the contact section or contact point, or at least reducing their transmission. The position of the contact point is more stable, resulting in less wear on the contact element and / or the mating contact element.

[0146] The compensating section can, for example, be provided or formed in the assembly section and / or in the fastening section and / or between the assembly section and the fastening section.

[0147] By incorporating at least one such compensating section, the advantage of a stamped and bent part with a relatively thin wall thickness and the resulting high elasticity or flexibility can be advantageously integrated into a robust, stiff extruded part that can be produced with a higher wall thickness.

[0148] If several left-curved and / or right-curved sections are provided, the compensating section can be designed, for example, in the form of an accordion or a leporello.

[0149] Extrusion advantageously allows for, for example, very tight curve radii relative to the wall thickness (e.g., inner curve radii that are smaller or significantly smaller than the wall thickness). This enables such a compensating section to be implemented efficiently in a small space. Furthermore, the wall thickness in the compensating section can be reduced compared to the rest of the assembly and / or fastening section.

[0150] It is particularly advantageous if the wall has at least one left-curved section and / or one right-curved section on both sides. However, it is also conceivable that the wall has at least one left-curved section and / or at least one right-curved section on only one side (for example, on the outside or on the inside).

[0151] According to a second aspect of the invention, a connector is proposed. R. 416213

[0152] - 25 -

[0153] The connector is designed for mating with a counterpart connector along one mating direction. The connector has a connector housing and a contact element as described above.

[0154] This advantageously provides a cost-effective, sustainable, and easy-to-manufacture connector. In particular, a connector designed to transmit high power and / or high currents and / or to operate at or with high voltages.

[0155] The connector is preferably designed for mounting on a component. The component can be, for example, an inverter, a battery, an electric machine, etc., in particular a component of an electrically powered vehicle (e.g., car, truck, boat, ship, airplane, helicopter, drone, etc.).

[0156] The connector can be attached to the component or a component housing, for example, by means of the connector housing, and in particular, it can be detachably attached, for example, by screwing it on. The connector can be coupled to a busbar of the component (e.g., screwed or riveted on, etc.), in particular by means of the contact element.

[0157] The contact element can be mounted or arranged in or on the connector, for example, in or on a connector housing, e.g., in a contact chamber of the connector housing. It can be molded, snapped, or pressed ("stitched") into or on the connector or its housing, etc. This fastening can take place, for example, in the mounting area of ​​the contact element.

[0158] The contact element can be designed to receive the mating contact element. Alternatively or additionally, it can be provided that the contact element is inserted into the interior of a mating contact element (e.g., if the latter is designed as a type of forked contact element).

[0159] The connector can be designed, for example, as a so-called pin header or as a knife-edge connector. R. 416213

[0160] - 26 -

[0161] For example, the connector may be designed to include a sensor, such as a temperature sensor. It may also be designed to include a control element, such as a control element for regulating or controlling the current flowing through the contact element. This control element may be, for example, a PTC element, a PTC resistor, or something similar.

[0162] Such a sensor or control element can be arranged, for example, on or within the contact element. In particular, the extrusion process makes it especially easy to provide a receptacle for such elements on or within the contact element, particularly close to the contact point between the contact element and the mating contact element. Such a receptacle can be formed, for example, in or on the contacting section. Alternatively or additionally, it can be arranged near the contacting section, for example, on, in, or on a web or strut. The receptacle can be designed—this is merely an example—in the form of a groove, so that the sensor and / or the control element does not protrude too far from the receiving structure. However, the receptacle can also be flat or protrude from the structure (as a kind of base or projection).

[0163] It may also be provided that the connector has a touch protection element made of an insulating material. This touch protection element may, for example, be in contact with the contact element at least partially, in particular at a free end of the contact element and / or on at least one side surface of the contact element.

[0164] Advantageously, such a touch protection element can have an edge running at an approximately 90° angle at one end where it rests against the contact element. This is because the contact element, manufactured as an extruded part, does not require a chamfered cut to reliably remove any stamping residue that could otherwise protrude into the trajectory of the mating contact element and damage its surface. However, such a stamped chamfer on a stamped and bent part necessitates filling the chamfered cut area of ​​the contact element to prevent damage to the contact lamellae, which could otherwise spring into a gap between the contact element and the touch protection element and then be scratched during subsequent insertion. This filling creates a [missing information - likely a specific feature or characteristic] on R. 416213

[0165] - 27 -

[0166] A touch protection element is a section that ends at an acute angle (e.g. 45°). Such an acute angle is very difficult to manufacture reliably.

[0167] By using an extruded contact element, the need to remove stamping residue is advantageously eliminated. The angle at the free end or its end section is closer to 90°, and therefore the contact protection element can also be designed, for example, with an angle of approximately 90° at the connection point to the free end, thus significantly simplifying the manufacturing process of the contact protection element. It is understood that the end section at the free end of the contact element can, in principle, assume any desired angle. Preferably, the angle is in the range of 80° to 100°, and particularly preferably from 85° to 95°. The contact protection element can, for example, cover the narrow sides, the outer surface, and the free end face of the contact element.

[0168] According to a third aspect of the invention, a connector arrangement is proposed.

[0169] The connector assembly includes a mating connector, which in particular comprises a mating connector housing and a mating contact element. The connector assembly further includes a connector as described above.

[0170] This advantageously provides a cost-effective, sustainable, and easy-to-manufacture connector assembly. In particular, a connector assembly designed to transmit high power and / or high currents and / or to operate at or with high voltages.

[0171] The mating contact element can, for example, have a compacted end of an electrical conductor or be formed from one. Individual conductors or strands of the conductor can, for example, be formed into a solid, stiff, and / or rigid end (e.g., by force and / or heat). It can, for example, be provided that a mating contact element lamellar element is arranged or attached to the compacted end, which, in the mated state of the connector and mating connector, effects the electrical contact with the contact element, in particular at at least one contact point. Such a mating contact element lamellar element can, for example, have at least one, in particular elastic, R. 416213

[0172] - 28 - and / or elastically reversibly designed, lamella or contact lamella which contacts the contact element.

[0173] According to a fourth aspect of the invention, an electrical device is proposed.

[0174] The electrical device comprises one component. The component comprises a busbar. The component may also, for example, have a component housing. The electrical device also comprises a connector as described above. The connector may, for example, be arranged or attached to the component.

[0175] This advantageously provides a cost-effective, sustainable, easy-to-manufacture electrical device that is easy to connect to the mating connector. In particular, an electrical device designed to transmit high power and / or high currents and / or to operate at or with high voltages.

[0176] Drawings

[0177] Further features and advantages of the present invention will become apparent to the person skilled in the art from the following description of exemplary embodiments, which, however, are not to be interpreted as limiting the invention, with reference to the accompanying drawings.

[0178] They show

[0179] Figs. 1 a to 1 d: schematic representations of contact elements designed as stamped and bent parts for the transmission of high power from internal tests of the applicant;

[0180] Figs. 2 and 3: a schematic cross-section (Fig. 2) and a perspective cutaway view (Fig. 3) through elements of a high-power connector with extruded contact elements; R. 416213

[0181] - 29 -

[0182] Fig. 4: a schematic cross-section through an electrical device with one component, a connector attached to it with two contact elements manufactured as extruded parts and with a mating connector connected to the connector;

[0183] Figs. 5a, 5b: a schematic perspective view (Fig. 5a) of a contact element manufactured as an extrusion part and a cutaway perspective view of a contact element manufactured as an extrusion part;

[0184] Fig. 6: a comparison of a contact element manufactured as a stamped and bent part and a contact element manufactured as an extruded part;

[0185] Figs. 7a to 7f: schematic cross-sections through various contact elements, each manufactured as an extruded part;

[0186] Figs. 8 and 9: schematic cross-sections through contact elements manufactured as extruded parts;

[0187] Figs. 10a to 10d: schematic cross-sections through contact elements, each manufactured as an extruded part;

[0188] Fig. 11: Steps of a process for manufacturing a contact element as an extruded part.

[0189] Figures 1a to 1d show schematic representations of contact elements 1 designed as stamped and bent parts 60 for the transmission of high power (e.g. at least 1 kW or at least 5 kW), e.g. for use with or on power components of electrically operated vehicles, from internal tests of the applicant.

[0190] Figures 1a to 1c show perspective views of three different embodiments of such contact elements 1. Figure 1d shows a top view of one side of the contact element 1 from Figure 1c. R. 416213

[0191] - 30 -

[0192] The contact elements 1 of Figs. 1a to 1d are designed to be mounted or arranged in a connector 100 (not shown here, but see, for example, Figs. 2 to 4 for exemplary embodiments of a connector 100). The contact elements 1 are further designed for mounting, in particular detachable mounting, on a busbar 301 (see, for example, Fig. 4) of a component 300 (see, for example, Fig. 4) and for mating along a mating direction Z with a mating contact element 201 (see, for example, Figs. 4, 10c, 10d) of a mating connector 200 (see, for example, Fig. 4).

[0193] The contact elements 1 of Figs. 1a to 1d are each manufactured as stamped and bent parts 60 from a sheet of metal. They have a substantially constant wall thickness (the wall thickness of the sheet) in all sections 2, 4, 6. The shape shown is produced by stamping and bending processes of the initially flat sheet of metal.

[0194] The contact elements 1 of Figs. 1a to 1d have a contact section 2 at a first end 3, which is configured for contacting the mating contact element 201. They also have a mounting section 4 at a second end 5, which is configured for mounting on the busbar 301. Furthermore, they have a fastening section 6, which is configured for coupling, in particular detachable coupling, with a connector housing 101 of the connector 100 (see, for example, Figs. 2 to 4 for a connector 100 with a connector housing 101, but there with a different contact element 1).

[0195] The contact element 1 from Fig. 1a is designed as a (single) flat blade contact 7. The contact elements 1 of Figs. 1b to 1d are designed as fork contacts 8, each with two contact blades, a first contact blade 8a and a second contact blade 8b, wherein these contact blades 8a, 8b are arranged parallel and spaced apart from each other and have a distance D between them (a so-called "gap"). For example, a mating contact element 201 of a mating connector 200 can be inserted between the two contact blades 8a, 8b. An outer surface 18 of the contact elements 1 is also shown. R. 416213

[0196] - 31 -

[0197] Figures 1a to 1d show a Cartesian coordinate system that, in addition to the insertion direction, has an X-direction X and a Y-direction Y. The X-direction X can also be described here, for example, as the width direction, in which the width B ("overall width") of the contact element 1 or the assembly section width B1 of the assembly section 4 can be measured. The Y-direction Y can also be described here, for example, as the depth direction, in which the depth of the contact element 1 can be measured.

[0198] The contact surfaces of the contacting sections 2 run in a contact plane KE, which here is parallel to the YZ plane as an example.

[0199] In order to provide a secure and stable fastening of the respective contact element 1 to the busbar 301 of the component 300, it has proven advantageous in internal tests of the applicant to arrange a fixing element 50, here exemplified as a nut 51, on the mounting section, so that a material reinforcement is provided and / or a (sufficiently long) thread for a screw can be provided.

[0200] The fixing element 50 is attached in an additional work step in the progressive die tool in or on the assembly section 4 after the stamped and bent part 60 has been formed, e.g. by pressing it in or by a material-fit connection. To enable this assembly process, an additional assembly space must be provided, which increases the width B and also the width of the assembly section B1, as well as increasing the length L1 of the assembly section (by more than the length or height of the fixing element 50).

[0201] Forming the correct direction of the fixing element 50 for mounting on the busbar 301 (e.g. in the plug-in direction Z or at an angle to the plug-in direction Z) and mounting the fixing element 50 on the contact element 1 results in additional punching and / or bending processes and increases the dimensions of the contact element 1 (width B, mounting section width B1, mounting section length L1).

[0202] Furthermore, it has proven advantageous that, in the area of ​​mounting on the busbar 301, the contact element 1 has a bearing contact surface to the busbar 301 that corresponds at least to the cross-section of the conductor to which the busbar 301 is connected or which the busbar 301 has. For example, if a conductor cross-section R is specified for a particular current-carrying capacity. 416213

[0203] - 32 - of 50mm 2 If so, the contact surface of contact element 1 should be at least 50mm 2This applies to conductor cross-sections of, for example, 50 mm². 2 A sheet metal wall thickness of, for example, 1.8 mm to 2.6 mm may be useful to achieve sufficient current-carrying capacity, with a conductor cross-section of, for example, 150 mm². 2 Depending on the depth of the contact section 2, the sheet thickness can be approximately...

[0204] 5 mm. At the same time, to avoid excessive stress in bent sections of the contact element 1, it is advisable to select an inner radius that is no smaller than the wall thickness of the sheet metal used to manufacture the stamped and bent part 60. To generate a sufficiently large bearing contact area, taking the bending angles into account, the contact elements 8, designed as fork contacts 8 in Figures 1b to 1d, therefore have a width B of the contact element 1 that extends over a considerable length along the insertion direction Z. In other words, it is not possible to design the contact element 1 in the assembly section 4 with a smaller width B or to significantly reduce the length along which this width B extends. This requires a considerable amount of space in the connector 100. The assembly section length L1, and thus the extension length L, is also affected, among other things.increased by the necessary bending radii and the manufacturing space requirements.

[0205] In the contact element 1 from Fig. 1a, the fastening element (not shown here) for attaching the contact element 1 to the busbar 301 runs perpendicular to the insertion direction Z, here by way of example parallel to a contact plane KE in the Y direction Y (contact with the mating contact element of the mating connector takes place in the contact plane KE). To position the fixing element 50 approximately flush below the flat blade contact 7, three bending operations at large angles (here, for example, by approximately 90° each) are required. The first bending section below the contact section 2 is necessary to create sufficient space to the side (parallel to the X direction X) to position the fixing element 50 in the desired position below the contact section 2 after the two subsequent bending operations, and also to ensure that the necessary inner radii are not undercut.For the installation of the fixing element 50, additional space is required in the X-direction, which significantly exceeds the width of the fixing element 50. Furthermore, the three bending operations of approximately 90° each (solely to position the fixing element 50 in the correct direction and position) necessitate an expensive R. 416213 due to the sheet thickness required for current-carrying capacity and the required manufacturing tolerances.

[0206] - 33 -

[0207] Tool. In the contact element 1 from Fig. 1a, a profile 14 is provided in the mounting section 6, which is intended to improve the retention of the contact element when it is pressed into a connector housing 101. This profile 14 must be laboriously milled into the sides of the wall after the contact element 1 has been manufactured. It can also be stamped into the die edges. However, this requires an additional step in the progressive die. Furthermore, it is not possible to stamp a profile, especially one deep enough, into the long side (parallel to the Y-direction Y) of the stamped and bent part 60, which would allow for a large-area locking or interlocking connection, e.g., during a press-fit operation, into a connector housing 101.

[0208] To enable secure mounting of the illustrated stamped and bent parts 60 in a connector housing 101, stamped and bent part undercuts 61 are arranged on the respective contact elements 1. These undercuts engage with (not shown) locking elements (e.g., locking lances or locking hooks) in the connector housing 101, thus securing the position of the contact element 1 in the connector housing 101. However, this requires a more complex design of the connector housing 101 compared to a press-fit or press-fit assembly ("stitching"). Furthermore, a snap-fit ​​assembly, compared to a press-fit assembly, is only possible with a certain amount of play between the contact element 1 and the connector housing 101, as manufacturing tolerances must be taken into account.

[0209] In the contact elements 1 shown in Figs. 1b to 1d, attachment to the busbar 301 is provided by a fastening element along the insertion direction Z or along the longitudinal axis of the contact element 1. In this embodiment, the design of the contact elements 1 as a stamped and bent part 60 and the provision of the fixing element 60 result in an extension of the contact elements 1's overall length L (here in the insertion direction Z) that exceeds the height of the fixing element 50 (here: the nut 51). This is because the fixing element 50 must be positioned, sufficient space must be available for the fastening process, and the bending radii must not be reduced. Furthermore, the space requirement in the X-direction X also increases, as the walls of the stamped and bent part 60 must extend around the fixing element 50 in the assembly section 4. In the contact element 1 of Fig.1 b the walls are extended from the two contact knives 8a, 8b and are bulged out in a jug-like shape around the fixing element 50, which is on the bottom of this jug R. 416213.

[0210] - 34 - is arranged. In the contact element 1 of Figs. 1c and 1d, the walls are first brought towards each other in extension of the two contact blades 8a, 8b and then together guided around the area of ​​the fixing element 50 in the form of a “C”.

[0211] Due to the springy properties of the sheet metal used for these stamped and bent parts, the dimensions of the illustrated contact elements 1 exhibit relatively high (manufacturing) tolerances unless the contact element 1 is stabilized by further steps, such as bending in stabilizing sections (see, for example, Figs. 1b to 1d in the area between the contact blades 8a, 8b). These stabilizing sections are firmly connected to each other by a type of tongue-and-groove joint ("clinched"). The stabilizing section created by the bending process also prevents the stamped and bent part from being secured in the connector housing, for example, by press-fitting. This is because the stabilizing section should not be subjected to radial (lateral, here perpendicular to the insertion direction z) stress within the connector housing 101. This would negatively affect the tolerance dimensions of the distance D between the two contact blades 8a, 8b.As described above, the most advantageous solution here is therefore to fasten the contact element 1 of Figs. 1 b to 1d in the connector housing 101 by means of the stamped-bent part undercut 61.

[0212] It is further understood that, in the case of such contact elements manufactured as stamped and bent parts 60, at least one further processing step, such as a drilling process, etc., may be necessary before, during or after completion of the manufacturing process (in the progressive die), e.g. to create an opening.

[0213] Based on these internal findings from the applicant's development activities, the applicant has developed a contact element 1 which, surprisingly, enables simple and cost-effective manufacturing (despite the absence of standard pre-products such as rolled sheet metal) by eliminating the need for stamping and bending. It is stable, allows for low manufacturing tolerances, enables smaller dimensions (especially in the section(s) adjoining the contact section 2), is easy to attach to a busbar, and allows for variable adjustment of the contact element's mounting position on the busbar. R. 416213

[0214] - 35 -

[0215] Figures 2 to 10d, which are described together below, show embodiments of such a contact element 1, partially mounted in or on a connector 100.

[0216] Figures 2 to 10d show (at least) one contact element 1 for a connector 100 (see Figures 2 to 4), the contact element 1 configured for, in particular detachable, mounting on a busbar 301 (see Figure 4) of a component 300 (see Figure 4) and for mating along a mating direction Z with a mating contact element 201 (see Figure 4) of a mating connector 200 (see Figure 3). The contact element 1 has a contact section 2 at a first end 3, wherein the contact section 2 is configured for contacting the mating contact element 201. The contact element 1 further has a mounting section 4 at a second end 5, which is configured for mounting on the busbar 301. The contact element 1 also has, by way of example, a fastening section 6 which is designed for coupling, in particular detachable coupling, with a connector housing 101 of the connector 100.It has now been surprisingly shown that the problems described in connection with the contact element 1 of Figs. 1 a to 1d, which is designed as a stamped and bent part 60, can be easily solved by manufacturing the contact element 1 as an extruded part 40.

[0217] Component 300 is specifically a component 300 of a vehicle. The connector 100 and / or the contact element 1 can, for example, be used in or on a vehicle.

[0218] It can be particularly advantageous for the contact element 1 to be manufactured in one piece or integrally (it is understood that the introduction of a recess or opening (e.g. by drilling, etc.) and / or a surface coating or electroplating having e.g. tin, silver, gold, etc. does not preclude one-piece manufacturing).

[0219] In other embodiments, for example, a further element, e.g. a contact element lamellar element, can be arranged or attached to contact element 1 after manufacture, wherein such an exemplary contact element lamellar element is attached, e.g., to or in the contacting section (e.g. force-fit, R. 416213).

[0220] - 36 - form-fitting or material-fitting, e.g. by laser welding or soldering or gluing) and / or has at least one contact lamella.

[0221] Alternatively or additionally, a sensor 35 (e.g., a temperature sensor, current sensor, accelerometer, etc.) and / or a control element 36 (e.g., a current control element, e.g., a PTC element) can be provided on or in the contact element 1, or a recess or defined location can be provided on or in the contact element 1 in which such a sensor 35 or control element 36 can be arranged. Preferably, this recess or defined location is designed such that the element 35, 36 projects as little as possible into an external space or an internal space of the contact element 1. The installation space or footprint of the contact element 1 is thus advantageously not increased, or only slightly increased, despite the additional functionality. Such an element (sensor 35 and / or control element 36) can, for example, preferably be arranged near or on or in the contact section 2 (or the recess or defined location can be located there).(the defined location can be provided there). In Fig. 2, various exemplary positions are shown on the left contact element 1 where a sensor 35 and / or a control element 36 can be arranged. Here, these positions are given by way of example by recesses (here in the form of a contact section groove 19), whereby these recesses are provided here by way of example on the respective outer side 18 or on a side of the respective contact blade 8a, 8b facing away from the contact plane KE. Further positions are shown on or section by section in a strut 33 or on a web, which will be described below. One example is on a side of the strut 33 or the web facing the contact section 2 (here in a receptacle designed as a groove in the web or the strut 33), and one is on a side of the strut 33 facing away from the contact section 2 (here on a continuous plane of the strut).It is understood that only one of the elements 35, 36 may be provided on the contact element 1 and / or that the elements 35, 36 may be interchanged in Fig. 2. It may also be provided that the strut 33 or the web has a (particularly groove-like) recess or receptacle on both sides, or has a flat surface on both sides. In principle, the formation of a projection or base extending from the surface as a receptacle is also conceivable. No such elements 35, 36 are shown as an example on the right-hand contact element 1 in Fig. 2, although this contact element 1 could, in principle, also have at least one such element. R. 416213.

[0222] - 37 -

[0223] Elements 35 and 36 could be present. Such elements 35 and 36, as well as exemplary arrangement positions, are also shown by way of example in Figures 7c and 7d. In Figure 7c, they are shown by way of example in recesses in the form of contact section grooves 19, here by way of example on the outer side 18 or on a side of the contact blades 8a and 8b facing away from the contact plane KE. In Figure 7d, they are shown by way of example on different sides of the strut 33 or the web.

[0224] The contact element 1 can be made of, for example, a material that is electrically and, if necessary, thermally conductive, and in particular predominantly (e.g., at least 50%, preferably at least 80%, and most preferably at least 95%) a metal. It can, for example, be made predominantly of: aluminum or an aluminum alloy, or copper or a copper alloy, or silver or a silver alloy. The contact element 1 can have a (thin) coating, e.g., of tin, silver, gold, etc. This can prevent (contact) corrosion, reduce contact resistance, and / or reduce friction during mating. Such a surface layer can be applied, for example, by an electroplating process. Such a coating can, for example, have a thickness of, for example, a maximum of 50 micrometers, preferably a maximum of 30 micrometers, and most preferably a maximum of 10 micrometers.

[0225] In the embodiments shown here, the Y-direction Y runs parallel to an extrusion direction SR (with the exception of Fig. 10d, in which the insertion direction Z runs along the extrusion direction SR).

[0226] The contact elements 1 shown here as an example in Figures 2 to 10d, manufactured as extruded parts 60, all exhibit the following characteristics: high stability, high torsional stiffness, low tolerances (especially with regard to the extension length L, the distance D between adjacent contact blades 8a, 8b in fork contact 8 designs, and the width B), and great flexibility with regard to the arrangement or adaptation of mounting points in the assembly section 4 (see, for example, Figures 7a to 7d). Depending on the arrangement of the assembly section 4 relative to the mounting section 6, they can have a significantly shorter extension length L and / or width B (and / or depth) compared to the stamped and bent parts 60 from Figures 1a to 1d. This is illustrated by way of example in Figure 6, which is described below. Furthermore, for example, R. 416213 can be easily

[0227] - 38 -

[0228] Wall thickness variations (especially in or between the different sections 2, 4, 6) can be easily implemented and / or cavities can be formed. Furthermore, thickness changes and / or thickness transitions can be easily implemented. Undercuts can be easily formed and / or stability-enhancing structures (e.g., at least one brace 33) can be formed in or on the contact element 1. Such contact elements 1 can have a slim design, which is made possible by manufacturing them as an extruded part 40. Here, they all extend by way of example along an axis that, by way of example, runs parallel to the insertion direction Z (Figs. 2 to 10c) or parallel to the Y-direction Y (Fig. 10d). The contacting section 2, the assembly section 4, and the fastening section 6 arranged between these sections 2 and 4 are arranged by way of example along a line.This results in a very slim footprint perpendicular to the insertion direction Z (Figs. 2 to 10c) or perpendicular to the Y direction (Fig. 10d), in particular a small width B.

[0229] Figure 11 shows an example of a possible method for manufacturing such a contact element 1.

[0230] In step 700, a tool for extrusion, in particular with a die or a mold, is provided.

[0231] In step 710, an initial element, e.g., a so-called pressed part (e.g., a rod-shaped element, e.g., made of metal), is extruded in or by means of the tool. A profile element, e.g., rod-shaped, is the result of this step.

[0232] In an optional step 715, a surface coating is applied. This can be done, for example, by electroplating. A single, particularly thin, layer or several, particularly thin, layers can be applied. Such a layer can, for example, consist of tin, zinc, nickel, copper, silver, platinum, gold, etc., particularly as a predominant material. It is understood that step 715 can be performed at any point in the further process sequence after step 710 (step 715 is shown here by way of example as a dashed box to indicate that it is an optional step). It is further understood that in step 715 the workpiece to be processed can be coated completely or only partially, for example. R. 416213

[0233] - 39 - or that different sections can be provided with different coatings. Preferably, the contacting section 2 and / or the assembly section 4 is coated in step 715. It is further understood that step 715 can be repeated multiple times (e.g., for applying different layers and / or after different process steps).

[0234] In particular, in step 715 the contact surfaces in the contacting section are silver-plated, possibly with an intermediate layer between the material of the contact element 1 and the silver layer, e.g. by an intermediate layer of nickel.

[0235] In step 720, the profile element is cut or cut to length. The cutting is carried out in particular into individual contact elements 1 or – especially if optional further steps follow – into individual contact element blanks.

[0236] As an optional step, for example, in step 730 (at least), an opening 9 can be created in the profile element (e.g., before step 720 of cutting or trimming the profile element) or in the contact element 1 or in the contact element blank, particularly in the assembly section. This step should include the creation of a thread 28 or (if an opening 9 is already present) only the thread creation step. The opening 9 can be created, for example, by drilling, milling, EDM, etc. In particular, this opening can be designed to mount the contact element 1 on the busbar 301. If the profile element is first cut into (larger) sections, which are later further cut into several contact elements 1, step 730 of creating (at least) one opening can also be performed on this intermediate product (the section).

[0237] As an optional step, for example, in step 740 (at least), another element can be attached to the profile element (e.g., before step 720 of cutting or trimming the profile element) or to the contact element 1 or the contact element blank. For example, a contact element lamellar element can be attached to the contact element 1 or the contact element blank, and / or a sensor 35 and / or a control element 36. If the profile element is first cut into sections that are later further divided into several contact elements 1, see R. 416213.

[0238] - 40 - can be divided, so step 740 of attaching (at least) one further element can in principle already be carried out on this intermediate product.

[0239] It is understood that the order of at least steps 715, 720, 730, and 740 can be reversed. As described above, step 715, in particular, can occur at any position after step 710, and step 715 can also occur multiple times consecutively and / or after or before different steps 720, 730, and 740 (to illustrate this, step 715 is shown here after each of steps 710, 720, and 730 with a dashed box to represent an optional step).

[0240] Figures 2 to 4 show a connector 100 for mating with a mating connector 200 (see Fig. 4) along a mating direction Z. The connector 100 is, for example, configured for mounting on a component 300 (see Fig. 4). The connector 100 has a connector housing 101 and (at least) one contact element 1 as described above (and below). Here, two contact elements 1 are provided in the connector 100.

[0241] The connector housing 101 has, by way of example, two contact chambers 102. A contact element 1 is mounted in each of the two contact chambers 102. The contact element 1 can, for example, be mounted in the associated contact chamber 102 along a mounting direction BR, e.g., inserted or pressed in. It can, by way of example, be held in the contact chamber 102 by a latch (see Fig. 8, left side) and / or by a clamp (stitch mounting, see Figs. 2 to 4 and 8, right side).

[0242] The exemplary contact chamber 102 here has an exemplary contact chamber wall 105. This contact chamber wall 105 has several steps 106 on its inner side. These steps 106 result in successively smaller inner diameters of the contact chamber 102 (along a mounting direction BR of the contact element 1 into the contact chamber 102). In other words, the diameter of the contact chamber 102 decreases with each subsequent step. A continuous, e.g., conical, tapering of the inner diameter of the contact chamber 102 is also possible (see, e.g., Fig. 3). Such a stepped or continuous tapering of the inner wall of the contact chamber facilitates easier mounting of the contact element 1 in the R. 416213.

[0243] - 41 -

[0244] Connector housing 101 is inserted via a type of insertion funnel. Simultaneously, a profile 14, described below (e.g., a fir-tree-shaped profile), can facilitate or improve the interlocking of projections 13 of the profile 14 (see also Figs. 5a, 5b) in the contact chamber wall 105, since successive projections 13 are not guided into already scratched or grooved sections in the inner wall of the contact chamber wall 105. Rather, during insertion, molten areas (frictional heat) of the contact chamber wall 105 behind the projections 13 can solidify, thus advantageously anchoring the contact element 1 with particularly high positional accuracy in the connector housing 101 (especially compared to locking by means of a locking lance or a locking hook, etc., as described above in relation to Figs. 1a to 1d in connection with the stamped-bent part undercut 61).

[0245] Figures 2 to 4 also show a contact protection element 107. Figure 4 shows an end section 108 of the contact protection element 107. The contact protection element 107 is shown here only as an example of part of the contact chamber 102. The end section 108 of the contact protection element is arranged at a free end 37 of the contact element 1 and faces the mating contact element 201. Because the contact element 1 is manufactured as an extruded part 40, a stamped chamfer is not necessary at the free end 37 (see, for example, Figures 1b to 1d) – in contrast to a stamped and bent part 60 – to prevent the protrusion of stamping residue from the stamping of the actual contact section into the trajectory of the mating contact element 201 and damage to its surface. Rather, the free end 37 can form an angle of approximately 90° here in the region of the end section 108. As a result, the end section can also form an angle of approximately...exhibit 90° and an acute angle (e.g. 45°) is not necessary to prevent a gap between free end 37 and end section 108.

[0246] Figure 4 shows a connector assembly 400. This assembly comprises a connector 100 as described above and a mating connector 200. The mating connector 200 is shown here by way of example with a mating connector housing 202 and a mating contact element 201. The mating contact element 201 is shown here, by way of example, as a compacted end 203 of an electrical conductor 204 (see also Figures 10c, 10d). It is shown here, by way of example, that the mating contact element 201 has a mating contact element lamellar element 205 on its outer surface (this can be, for example, attached to the R. 416213).

[0247] - 42 -

[0248] The counter-contact element 201 is attached, e.g. by positive locking, force locking or material locking, e.g. by a welding process, e.g. by laser welding, or a soldering process or an adhesive process. The counter-contact element lamellar element 205 can, for example, have at least one contact lamella that contacts the contact element 1 (in Fig. 4: the inner surface 29 of the contact blades 8a, 8b described below).

[0249] The connector assembly 400 is shown here as an example of a sealed connector assembly 400. The mating connector 200 is designed here as an external plug that receives a collar of the connector 100 in the mating connector housing 202. A radial seal 206 is arranged on the mating connector housing 202 (here on the outside of the mating connector housing), which provides a seal against the connector housing 101 (here: at the collar).

[0250] Figure 4 also shows an electrical device 500. The electrical device 500 has a connector 100, as described above. It also has a component 300 with a busbar 301. The component 301 also has, by way of example, a component housing 303.

[0251] Connector 100 is shown here as an example of a so-called pin header or knife-edge connector. Connector housing 101 is shown here as an example of attachment to component housing 301, e.g., screwed in place. Connector 100 can be sealed against component housing 301 by a connector seal 104, e.g., an axial seal.

[0252] The contact elements 1 shown in Figures 2 to 10d are designed to transmit high power, in particular at least 1 kW, at least 10 kW, or at least 50 kW. They are further designed, for example, to transmit high electrical currents, e.g., at least 1 A, at least 5 A, at least 10 A, at least 50 A, or at least 100 A.

[0253] They are also designed, by way of example, to be arranged or mounted in a connector 100 designed as a high-voltage connector (HV connector), or they are designed to withstand high voltages (e.g., in R. 416213).

[0254] - 43 - to be operated at at least 40V or at least 60V or at least 100V).

[0255] It is shown here, by way of example, that component 300 (see Fig. 4) is designed as a high-voltage (HV) component. It can be selected, for example, from the group consisting of: a voltage converter, in particular an inverter 302; an energy storage device, in particular a battery; an electric machine. In Fig. 4, the component is shown by way of example as an inverter 302, in particular as an inverter for an electrically powered vehicle.

[0256] The contact element 1 can be selected, for example, from the group: a knife contact, in particular a flat knife contact 7 (see, for example, Fig. 7a); a fork contact 8 (see Figs. 2 to 6 and 7b to 10d) with at least two contact knives 8a, 8b spaced apart from each other, in particular by a distance D, and in particular parallel to each other.

[0257] In the illustrated embodiments of fork contacts 8, it is provided – merely by way of example – that the mating contact element 201 can be inserted between the two contact blades 8a, 8b. Thus, here – only by way of example – the inner surfaces 29 and not the outer surfaces 18 of the contact element 1 are contacted. In other embodiments, contacting the outer surfaces 18 may be provided alternatively or additionally.

[0258] The contact blades 8a, 8b each have a contact plane KE which here runs parallel to the YZ plane.

[0259] Here, by way of example, in the contact elements 1 of Figures 2 to 10d, an opening 9 for inserting or passing through a fastening element 10 is provided in assembly section 4 (at least). The opening 9 can, by way of example, be designed as a through-hole 11 (Figures 2 to 5, 7 to 10c) or as a blind hole 27 (Figures 6, 10d). The opening 9 can have a smooth inner wall. Alternatively, it can also have (at least partially) a thread 28 (see Figures 4, 6, 10d). R. 416213

[0260] - 44 -

[0261] The fastening element 10 can, by way of example, be designed as a screw 30 (see right side of Fig. 4) or as a rivet (see left side of Fig. 4).

[0262] The opening 9 can be introduced - as described above in connection with Fig. 11 - e.g. after the extrusion process or already be present in the contact element 1 during the extrusion process.

[0263] The opening 9 (or a plurality of such openings 9) can, for example, run parallel to the insertion direction Z or parallel to the contact plane KE and perpendicular to a contact direction (between contact element 1 and mating contact element 201 – a contact normal force can act parallel to this direction, for example), which here runs parallel to the X direction. Such openings 9 are shown, for example, in Figures 2 to 6, 7b, 7c, and 8 to 10c.

[0264] This allows for the provision of a particularly short and narrow, or overall compact, contact element 1, which, compared to a stamped and bent part 60, can have a significantly shorter extension length L and / or a smaller width B and / or mounting section width B1, or a smaller footprint (especially in the X-direction X). This is illustrated by way of example in Figure 6 by comparing a contact element 1 as a stamped and bent part 60 (left) and a contact element 1 as an extruded part 40 (right). It can be seen that this reduction in extension length by a difference length Ldiff can be, for example, at least 1 mm, preferably at least 3 mm, or at least 10% or at least 20% of the extension length of the extruded contact element 1.This is possible because the assembly section length L1 of the contact element 1 (left), designed as a stamped and bent part 60, is not only shorter than that of the contact element 1 designed as an extruded part 40 (due to the unnecessary bending radii and manufacturing space requirements), but also because the assembly section 4 can easily be designed parallel to the fastening section 6 (overlapping). In this case, the difference in length Ldiff can, for example, be in the range of 15 mm to 25 mm and be, for example, 20 mm or 21 mm. It can be more than 25% of the extension length L of the stamped and bent part 60 on the left side. The shortening can be due, for example, to the fact that the contact element 1 designed as an extruded part 40 does not require a separately mounted fixing element 50, which not only requires its own height but also space (in the Z-direction and in the X-R direction). 416213.

[0265] - 45 -

[0266] direction X) is required for the assembly process of the fixing element 50 on the contact element 1 (see also the description of Figures 1a to 1d above). The width B of the contact element, which is designed as a stamped and bent part 60, is primarily dominated by the assembly section width B1, which significantly exceeds the width in the fastening section 6 and the contacting section 2. For the contact element 1, which is manufactured as an extruded element 60, the width B corresponds here, by way of example, to the assembly section width B1 (even if a profile 14 were also present, the width B could be less than the width B of the stamped and bent part 60).

[0267] The opening 9 (or a plurality of such openings 9) can, for example, run parallel to the extrusion direction SR (see Fig. 7e). This advantageously allows the contact element to be manufactured without a separate step of creating the opening after completion of the extrusion step. It is understood that, even in these embodiments, the opening 9 can be created by a separate process (e.g., drilling) (see above: step 730) and / or that an additional opening 9 can be created by such a separate process. Alternatively, a thread 28 can be cut into the opening 9 in a separate process step (which is assigned to step 730 in Fig. 11).

[0268] The opening 9 (or a plurality of such openings 9) can, for example, run perpendicular to the insertion direction Z and, in particular, parallel to a contact plane KE of the contacting section 2 (see Figs. 7e and 10d) - in these embodiments, the opening 9 runs parallel to the Y direction Y; however, only in Fig. 7e is it also parallel to the extrusion direction SR, this is due to the different insertion directions (180° insertion in Fig. 7e vs. 90° insertion in Fig. 10d).

[0269] The opening 9 (or a plurality of such openings 9) can, for example, run perpendicular to the insertion direction Z and, in particular, perpendicular to the contact plane KE of the contacting section 2 (see Figs. 7a, 7d and 7f - in these embodiments, the opening 9 runs parallel to the X-direction X and thus, by way of example, also perpendicular to the extrusion direction SR).

[0270] In Fig. 7f, the mounting section 4 has a particularly small mounting section width B1. Here, it is only approximately 50% of the width B or the outer dimensions in the contacting section 2. Mounting section 4 is not R. 416213.

[0271] - 46 - is not arranged centrally below the contact section (as shown, for example, in Figs. 7a, 7d), but rather offset laterally outwards (here, for example, parallel to the X-direction X) or shortened on one side (still in line with mounting section 6 and contact section 2). This enables a particularly space-saving connection to the busbar 301. The busbar 301 can, in principle, be mounted (e.g., screwed in) directly below the mounting section 6 next to the connection area or opening 9. This allows for a very compact connector housing 101 with respect to the insertion direction Z.

[0272] A particularly short extension length L can be achieved, for example, if the mounting section 4 and the fastening section 6 overlap (at least partially), see Figs. 6, 7b, 8, 9. The overlap can form, in particular, when viewed in a direction perpendicular to a fastening direction BR of the contact element 1 in the connector housing 101 or a contact chamber 102 of the connector housing 101. In other words, in a projection along a direction perpendicular to the fastening direction BR, an overlap of the mounting section and the fastening section results.

[0273] Such an overlap can be achieved particularly easily using the proposed extruded contact element 1.

[0274] The contact element 1 has a first wall thickness D1 in the contacting section 2, a second wall thickness D2 in the mounting section 4, and a third wall thickness D3 in the optional fastening section 6. As can be clearly seen, for example, in Figures 7a and 9 (left side), the first wall thickness D1 can differ, in particular by at least 10% or at least 25%, from the second wall thickness D2 and / or, in particular, from the third wall thickness D3. This allows the mechanical and electrical requirements of the individual sections 2, 4, and 6 to be specifically addressed without the need for complex (multiple) forming processes. The degrees of freedom in the design and geometric configuration (e.g., depending on electrical, mechanical, thermal, spatial, and other requirements) of the contact element 1 as an extruded part 40 are thus considerably improved compared to a design as a stamped and bent part 60.Producing such wall thickness variations is particularly easy for the proposed extruded contact element 1. Furthermore, R. 416213 can be easily achieved.

[0275] - 47 -

[0276] Changes in thickness (e.g. with angles from 75° to 105°, especially 90°) or smooth transitions between different wall thicknesses can be easily achieved.

[0277] Figure 9 shows various design options for a single contact element 1, which can increase its functionality, for reasons of space saving. On the left is a situation with different wall thicknesses D1, D2, D3 (here, the second wall thickness D2 and the third wall thickness D3 are only shown as examples; they can also differ, see, for example, Figures 5a, 5b, 7b, 7d, 7f), and on the right is a design with cooling fins 34, which are described below. It is understood that the left side can also be implemented on the right side, and vice versa.

[0278] It may be provided that a groove 12, in particular open to the outside, is provided in the fastening section 6 (see e.g. Figs. 7a, 7c to 7f, 8 (left side), 10a to 10d).

[0279] Figure 8 on the left clearly shows that this groove 12 – in addition to saving material – enables, for example, the simple assembly or fastening of the contact element 1 in the connector 100, in the connector housing 101, or in the contact chamber 102. For example, a locking device, particularly one designed to be elastically reversible, such as a locking lance 103, can be provided there. This locking device (here, by way of example, the locking lance 103) can engage in the groove 12 or on a wall of the groove 12 acting as an undercut after the contact element 1 has been inserted along the fastening direction BR into the connector 100.

[0280] Alternatively or additionally, at least one projection 13, particularly one directed outwards, can be provided in the fastening section 6 (see, for example, Figs. 2 to 5b, 8 (right side)). By means of the at least one projection 13, the contact element 1 can be held particularly well and securely in the connector 100, for example, in the case of a stitch connection (press-fit connection).

[0281] Alternatively or additionally, a profile 14 can be formed in the fastening section 6, in particular for locking and / or interlocking with the connector housing 101, in particular a fir tree profile 15 or a barbed profile, R. 416213

[0282] - 48 - see, for example, Figs. 2 to 5b, 8 (right side). A profile 14 can differ from a single projection 13 or a single groove 12 in that it has a plurality of elements such as groove 12 or projection 13. The fir-tree profile 15, for example, has a plurality of projections 13, wherein, parallel to a mounting direction BR of the contact element 1 in the connector 100, the projections 13 project at different distances from the center at the two ends (perpendicular to the mounting direction), preferably increasing continuously. In Figs. 2 and 4, it can be clearly seen that the steps 106 on the inner sides of the contact chamber walls 105 correspond to the fir-tree profile 15 (are approximately complementary to it). The fir-tree profile 105 can, for example, represent a barbed profile.

[0283] It is understood that the other figures may optionally also have such elements described above (groove 12, projection 13, profile 14, etc.) - these elements are not shown for the sake of clarity.

[0284] Figure 9 shows that on the right side of the contact element 1 shown, at least one cooling fin 17 (here: a plurality of cooling fins 17) is formed on the contact element 1, in particular on the outside 18 of the contact element 1.

[0285] The cooling fin 17 can, for example, have a cooling fin height HK (here: to be dimensioned parallel to the insertion direction Z) and a cooling fin width DK (here: to be dimensioned parallel to the X direction X). The cooling fin 17 can differ from the projection 13 or profile 14 described above, for example, in that it is designed (primarily) for or optimized to dissipate heat from the contact element 1 and / or that it has a coolant width DK that is, for example, at least 10% or at least 20% of the wall thickness of the adjacent wall from which it projects, and / or that it has a coolant height HK that is, for example, at least 10% or at least 20% of the wall thickness of the adjacent wall from which it projects.

[0286] The at least one cooling fin 17 (here a plurality of cooling fins 17) is arranged here by way of example in the contacting section 2, in particular on a side that faces away from the side contacted by the mating contact element 201. R. 416213

[0287] - 49 -

[0288] In the exemplary embodiment of Fig. 9, at least one additional cooling fin 17 (here: a plurality of cooling fins 17) is arranged in the mounting section 6, in particular on an outside of the mounting section 6.

[0289] In the exemplary embodiment of Fig. 9, at least one additional cooling fin 17 (here: a plurality of cooling fins 17) is arranged in the assembly section 4, in particular on an outer side of the assembly section 4.

[0290] Figures 10c and 10d each show an example of a contact element 1 in which the contacting section 2 has different wall thicknesses.

[0291] In Fig. 10c, a contact element 1 is shown as a fork contact element 8, in which a contact section projection 20 is provided (here: two contact section projections 20 facing each other). These are arranged here by way of example on the inner surfaces 29 of the contact element 1 in the contact section. They are designed here by way of example as a stop 22 for the mating contact element 201. When the connector 100 is plugged together with the mating connector 200, the at least one contact section projection 20 can prevent the mating contact element 201 from being positioned too deep in the contact section 2 relative to the contact element 1. Such a contact section projection 20 is also conceivable for a single contact blade (see, for example, Fig. 5a).

[0292] In Fig. 10d, a contact section projection 20 (first contact knife 8a) and a contact section groove 19 (second contact knife 8b) are provided on the inner surfaces 29 of the two contact blades 8a, 8b. In this case, the two elements 19, 20 are configured as coding means 21 for the mating contact element 201. The mating contact element 201 is shown here as an example of a compacted end 203 of an electrical conductor 204. The conductor 204 has a plurality of strands 207 on the inside and insulation 208 on the outside. At the end of the conductor 208, the insulation 208 is removed, and the conductors (here: strands) are compressed together, for example by pressure and / or temperature, to form a rigid, block-like body, the compacted end.For coding purposes, the mating contact element 201 (here: shown here as an example on its outer surface) has structures (groove / projection) that correspond to the contact section groove 19 and the contact section projection 20. This allows for assembly R. 416213.

[0293] - 50 - Connection of contact element 1 and mating contact element 201 is only possible if the correct mating contact element 201 is selected. In this case (Fig. 10d), the connection is made along the insertion direction Z pointing into the plane of the image (so-called 90° insertion compared to the other embodiments with 180° insertion), whereby in Fig. 10d the insertion direction Z corresponds by way of example to the extrusion direction SR. It is understood that for the coding at least one contact section groove 19 or at least one contact section projection 20 can be provided in / on each knife contact 8a, 8b. Or that at least one such element 19, 20 can be provided only in / on one of the two knife contacts 8a, 8b.

[0294] In Figures 2 and 7c, for example, a variable wall thickness is provided on the outer surfaces 18 of the knife contacts (here, by way of example, a contact section groove 19), which is configured as a receptacle for a sensor 35 (e.g., a temperature sensor) or a control element 36. These elements 35, 36 are received, arranged, or attached in this receptacle. The contact section grooves 19 here form, by way of example, the receptacles (recesses) for receiving or arranging such elements 35, 36. As a result, these elements 35, 36 do not protrude as far into the surrounding space and are also arranged closer to the locations relevant for heat generation. In principle, the elements 35, 36 could also be arranged on a contact section projection 20.

[0295] It is understood that elements such as a sensor 35 and / or a control element 36 may alternatively or additionally be arranged at other locations of the contact element (e.g. in the mounting section 4 or in the fastening section 6, etc.), e.g. on or in a strut 33 or a wall.

[0296] Figures 10a and 10b each show a contact element 1 having a compensating section 23. In Figure 10a, this section is arranged between the mounting section 4 and the fastening section 6, and in Figure 10b, it is located within the mounting section 4. It can also be located within the fastening section 6, or several compensating sections 23 can be provided, or the compensating section 23 can extend over more than one of the aforementioned sections 4 and 6. R. 416213

[0297] - 51 -

[0298] In the compensating section 23, a wall 24 of the contact element 1, in particular when viewed along the plug-in direction Z or along the mounting direction with the busbar 301, has at least one left-curved section 25 and / or at least one right-curved section 26. Figures 10c and 10d show, by way of example, several left-curved sections 25 and right-curved sections 26, wherein the two walls 24 in Figure 10c have these curvatures 25, 26 on their outer and inner sides, while in Figure 10d the walls 24 separated by the opening 9 have the curvatures 25, 26 only on their outer side (the side facing away from the opening 9).

[0299] This compensating section 23 allows a certain (form) elasticity or flexibility to the otherwise quite rigidly designed contact element 1, which facilitates, for example, mounting on the busbar 301, especially when manufacturing tolerances or assembly tolerances occur.

[0300] The compensating sections 23 can be easily formed in the extrusion process without having to cold-form a solidified material or induce stresses in the material. In principle, (non-continuous) shapes are also conceivable in the compensating section 23, e.g., transitions such as a "5" or an "S" with 90° angles between the segments or with angles greater than 90° (like a leporello fold), whereby such structures (especially with minimal or approaching zero or zero radii of curvature on their inner surfaces) are to be considered as curvature within the meaning of this application at their reversal points.

[0301] In some of the exemplary embodiments, the contact element 1, designed as an extruded part 40, has (at least) one cavity 32 (see, for example, Figs. 2 to 5e, 7c to 7f, 10a to 10d). This allows material to be saved and the contact element 1 to be made lighter (in terms of weight). By way of example, the contact element 1 can also have at least one bracing 33, in particular one integrally connected with several walls (see, for example, Figs. 2 to 5e, 7c to 7f, 10a to 10d). In the illustrated embodiments, the bracing 33 runs approximately at right angles to the walls to which it is connected. Here, by way of example, it runs in a plane perpendicular to the extrusion direction SR. Such a bracing 33 can, for example, be designed in the form of a web. See R. 416213

[0302] - 52 - can (e.g., in fork contacts 8, but also in (knife) contacts with only one contact blade) connect two spaced-apart walls, thereby mechanically stabilizing them, improving their current-carrying capacity, or better matching the electrical potentials of different parts of the contact element 1 (e.g., in high-frequency applications of the contact element 1). These walls can, for example, run parallel to each other. Such bracing 33 makes it possible to design the contact element 1 to be mechanically stable with minimal material usage and thus also with low weight, to stiffen it, and to reduce tolerances (e.g., in the case of large thermal fluctuations (e.g., due to high current)). In principle, such bracing 33 can also run at an acute or obtuse angle to at least one of the connected walls, thus allowing for a high degree of design freedom. It can, for example,It may also have a different thickness compared to the connected walls. For example, it may also have different thicknesses along its length, thus enabling further weight optimization. A sensor 35 and / or a control element 36 may also be arranged on it or (at least partially) in or on it. It may, for example, have a groove or a projection to receive such an element 35, 36. In other cases, it may receive one or more of these elements 35, 36 on a continuous plane.

Claims

R. 416213 - 53 - Claims:

1. Contact element (1) for a connector (100), the contact element (1) configured for, in particular detachable, mounting on a busbar (301) of a component (300), in particular a component of a vehicle, and for plugging together along a plugging direction (Z) with a mating contact element (201) of a mating connector (200); the contact element (1) comprising: - a contacting section (2) designed to contact the mating contact element (201) at a first end (3); - a mounting section (4) designed for mounting on the busbar (301) at a second end (5); - in particular a fastening section (6) designed for coupling, in particular detachable coupling, with a connector housing (101) of the connector (100); wherein the contact element (1) is manufactured as an extruded part (40), in particular in one piece.

2. Contact element (1) according to the preceding claim, wherein the contact element (1) is configured to transmit high power, in particular at least 1 kW or at least 10 kW or at least 50 kW, and / or the contact element (1) is configured to be arranged or mounted in a connector (100) designed as a high-voltage connector or to be operated at high voltages, and / or wherein the component (300) is configured as an HV component, in particular selected from the group: a voltage converter, in particular an inverter (302); an energy storage device, in particular a battery; an electric machine. R. 416213 - 54 - 3. Contact element (1) according to one of the preceding claims, wherein the contact element (1) is selected from the group consisting of: a knife contact, in particular a flat knife contact (7); a fork contact (8) with at least two contact knives (8a, 8b) spaced apart from each other, in particular parallel to each other.

4. Contact element (1) according to one of the preceding claims, wherein an opening (9) for inserting or passing through a fastening means (10) is provided in the assembly section (4), in particular a through opening (11) or a blind hole opening (27).

5. Contact element (1) according to the preceding claim, wherein the opening (9) extends parallel to the insertion direction (Z), or wherein the opening (9) extends parallel to the extrusion direction (SR), or wherein the opening (9) extends perpendicular to the insertion direction (Z), and in particular parallel to a contact plane (KE) of the contacting section (2), or wherein the opening (9) extends perpendicular to the insertion direction (Z), and in particular perpendicular to the contact plane (KE) of the contacting section (2).

6. Contact element (1) according to one of the preceding claims, wherein the mounting section (4) and the fastening section (6) overlap, in particular viewed in a direction perpendicular to a fastening direction (BR) of the contact element (1) in the connector housing (101).

7. Contact element (1) according to one of the preceding claims, wherein the contact element (1) has a first wall thickness (D1) in the contacting section (2), wherein the contact element (1) has a second wall thickness (D2) in the mounting section (4), in particular wherein the contact element (1) has a third wall thickness (D3) in the fastening section (6), wherein the first wall thickness (D1) differs, in particular by R. 416213 - 55 - at least 10% or at least 25% of the second wall thickness (D2) and / or especially of the third wall thickness (D3).

8. Contact element (1) according to one of the preceding claims, wherein a groove (12), in particular open to the outside, is provided in the fastening section (6), and / or wherein a projection (13), in particular directed outwards, is provided in the fastening section (6), and / or wherein a profile (14), in particular for locking and / or interlocking with the connector housing (101), is provided in the fastening section (6), in particular a fir tree profile (15) or a barbed profile.

9. Contact element (1) according to one of the preceding claims, wherein at least one cooling fin (17) is formed on the contact element (1), in particular on an outer side (18) of the contact element (1).

10. Contact element (1) according to the preceding claim, wherein the at least one cooling fin (17) is arranged: - in the contacting section (2), in particular on a side facing away from the side contacted by the mating contact element (201), and / or - in the fastening section (6), and / or - in the assembly section (4), in particular on an outside of the assembly section (4).

11. Contact element (1) according to one of the preceding claims, wherein the contacting section (2) has different wall thicknesses, in particular wherein a contacting section groove (19) and / or a contacting section projection (20) is provided in the contacting section (2), in particular configured as a coding means (21) for the mating contact element (201) and / or as a stop (22) for the mating contact element (201) and / or as a receptacle (34) for a sensor (35) or a control element (36). R. 416213 - 56 - 12. Contact element (1) according to one of the preceding claims, wherein the contact element (1) has a compensating section (23), in particular wherein the compensating section (23) is provided in the assembly section (4) and / or in the fastening section (6) and / or between the assembly section (4) and the fastening section, wherein in the compensating section (23) a wall (24) of the contact element (1), in particular viewed along the plugging direction (Z), has at least one left-curved section (25) and / or at least one right-curved section (26), in particular both at least one left-curved section (25) and at least one right-curved section (26).

13. Connector (100) for mating with a mating connector (200) along a mating direction (Z), the connector (100) being particularly designed for mounting on a component (300), the connector (100) comprising: - a connector housing (101); - a contact element (1) according to one of the preceding claims.

14. Connector arrangement (400), comprising the connector arrangement (400): - a mating connector (200) comprising in particular a mating connector housing (202) and a mating contact element (201), in particular having a compacted end (203) of an electrical conductor (204). - a connector (100) according to the preceding claim.

15. Electrical device (500), comprising the electrical device (500): - a component (300) with a busbar (301) and in particular with a component housing (303); - a connector (100) according to claim 13.

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