CN1672297A - 制造接触零件的方法 - Google Patents

制造接触零件的方法 Download PDF

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CN1672297A
CN1672297A CNA038180332A CN03818033A CN1672297A CN 1672297 A CN1672297 A CN 1672297A CN A038180332 A CNA038180332 A CN A038180332A CN 03818033 A CN03818033 A CN 03818033A CN 1672297 A CN1672297 A CN 1672297A
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马赛厄斯·施韦策
霍斯特·德莱恩
彼得·韦切
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    • H01R13/00Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
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    • H01R13/10Sockets for co-operation with pins or blades
    • H01R13/11Resilient sockets
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    • H01R13/00Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
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    • H01R13/115U-shaped sockets having inwardly bent legs, e.g. spade type
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    • H01R13/00Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
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    • H01R13/15Pins, blades or sockets having separate spring member for producing or increasing contact pressure
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    • H01ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
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    • H01R13/15Pins, blades or sockets having separate spring member for producing or increasing contact pressure
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    • H01R4/00Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
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    • H01ELECTRIC ELEMENTS
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    • H01R4/00Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/28Clamped connections, spring connections
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    • H01ELECTRIC ELEMENTS
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    • H01R13/00Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/02Contact members
    • H01R13/03Contact members characterised by the material, e.g. plating, or coating materials
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    • H01R13/00Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/02Contact members
    • H01R13/10Sockets for co-operation with pins or blades
    • H01R13/11Resilient sockets
    • H01R13/111Resilient sockets co-operating with pins having a circular transverse section
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Abstract

本发明公开了一种制造用于可拆式电插塞连接的导电接触零件(10)的方法,其中,提供一个包括一个部分纵向开槽的插座部分(23)的接触元件(20),该插座部分有沿其圆周分布地设置的肋片(26),以及提供一个可围绕该插座部分(23)和可覆盖其肋片(26)的、带有两个相对置的端侧端部(31、32)的套筒部件(30),按照本发明,该套筒部件(30)大体同轴于所述插座部分(23)地设置和定位,即,使它覆盖其肋片(26),并且该已定位的套筒部件(30)以其两个端部(31、32)之一在插座部分(23)上锁止。所述插座部分(23)自身围绕中心线(13)这样弹性地扭转,即,使其肋片(26)弧形地朝中心线(13)的方向曲拱,所述套筒部件(30)以其两个端部(32、31)的另一个在克服肋片(26)的弹性复位力保持扭转的插座部分(23)上锁止。所述具有规定的肋片(26)弹性的接触零件(10)可以以能重现的方式大批量生产制造。

Description

制造接触零件的方法
本发明涉及一种按照权利要求1前序部分所述的制造用于可拆式电插塞连接的导电接触零件的方法。
具有前言所述类型的接触零件的电插塞连接例如作为圆的插塞连接器用于马达和驱动装置的功率传输或在数据总线***和控制装置中用于在节点处的信号传输。所述电插塞连接的公母部分(凸凹部分)在这里各有一个可拆地装在一插套内的绝缘体,该绝缘体包括同轴于插接方向定向的用于容纳导电接触零件的孔。在电插塞连接母的部分中所述接触零件由接触插座构成,它在插塞连接时承接所述公部分中设计为触针的接触零件以构成电接触。本发明涉及制造用于插塞连接的母部分的设计为插座状的接触零件。
由德国公开文件DE 100 05 297 A1已知一种制造用于可拆式电插塞连接的导电接触零件,其中,提供一个包括笼型插座部分的接触元件,它有多个平行于轴线延伸且彼此隔开距离的肋片,以及其中提供一个可在插座部分的肋片上移动并具有一厚壁内端的护套。现在,所述插座部分接着通过转动一个规定的角度永久地扭转,优选地相对于其伸展的位置扭转10°。在接着的装配步骤中,沿插接方向在已如此变形的接触元件上套上护套并以其厚壁端部在前面压紧在其接触区上。插座部分扭转后的肋片通过扭转过程按双曲面的形状向内曲拱,以及总体上构成许多局部接触点,在插座部分内***触针时在弹性预紧力作用下这些接触点贴靠在触针圆周上。
在上述已知的制造方法中很难以可再现的方式实现向内曲拱的肋片的弹性特性,并因而很难达到肋片在一个***的触针上规定的压紧力。在已知的方法中为了达到永久地扭转例如10°,插座部分必须首先扭转一个待定的较大角度,以便所述变形的弹性部分在扭转松弛后留下塑性变形的状态。这种插座部分的所谓过度扭转对于材料的变动敏感,所以会产生一定量的废品。此外,扭转后的插座部分的肋片形成一种敏感易损的结构,在接着覆套护套时它可能受损,尤其当护套的厚壁端应以压配合固定在所述插座部分上时更是如此。
因此,本发明要解决的技术问题是提供一种制造前言所述类型的导电接触零件的方法,它允许插座部分的扭转有确定的可调性并因而可以在大批量生产时尽可能少出废品地以可重现的方式获得所述向内曲拱的肋片的弹性特性。
上述技术问题通过一种前言所述类型的具有权利要求1特征部分所述特征的方法来解决。为了在插座部分扭转过程中和在这之后保护肋片,按本发明的套筒部件事先以这样的方式大体同轴于插座部分地设置和定位,即,使它覆盖其肋片以及以其两个端侧端部之一在该插座部分上锁止。由此使敏感的肋片首先在进一步的工艺步骤中避免受外部的机械作用。通过在插座部分上锁止,所述套筒部件在接着的扭转过程中构成一个导引装置。现在,所述插座部分自身绕中心线扭转一个规定的角度(这一角度与肋片事先经研究其弹簧弹性特性得出的曲拱相匹配)以及在此状态保持克服肋片的弹性复位力。这一具有其特性的状态现在使之“冻结”,为此所述套筒部件以其另一端同样在插座部分上锁止。取决于插座材料和材料尺寸,所述肋片的机械特性可以通过插座部分的扭转调整为处于完全弹性范围内或也可调整为处于部分塑性范围内。
按本发明方法的一项有利的设计,套筒部件在插座部分上的锁止通过机械卡锁实现。作为替换方式,锁止也可以通过激光焊实现,这在加工技术上有生产速度高和加工精度高的优点。
按本发明方法的一种优选的实施形式,在已定位的套筒部件上冲压出一沿周向延伸的防扩张径向缩窄。因此,向内曲拱的肋片在插座部分内***触针时向外方向的弹性行程受到限制。所以通过这种机械止挡可以防止例如在插接过程中敏感的肋片过度拉伸。也就是说,避免由于可能产生的误差问题或在机械的强力作用下改变所述接触元件,由此保证在插塞连接工作中始终可靠的触点接通。此外,也可由此传输更大的电流。
按本发明方法的一项有利的设计,在接触元件上成形至少一个沿径向扩展的部段。通过这种扩展,在去往所述接触元件的未扩展部段的过渡部位处形成一个锁边,它例如与一插头部分的绝缘体的锁止元件配合作用。当接触零件***所述绝缘体的一承接孔内时,锁止元件沿径向向内处于锁边的后面,以便将接触零件沿轴向固定在绝缘体内。通过在接触元件不同的轴向位置成型沿径向扩展的直径不同的部段,可以使同一个接触零件应用于不同的对应设计的绝缘体。
由其他从属权利要求以及由附图表示的实施例给出本发明方法的其他优点,附图1至图5中分别用示意侧视图表示接触零件的接触元件和套筒部件处于按本发明的制造方法不同的工艺步骤。
按图1,在按本发明的制造用于可拆式电插塞连接的导电接触零件10的方法中,制备一个接触元件20和一个套筒部件30。在一个未表示的在这之前的工艺步骤中,按规定的划分距离(节距)由一带材重复地冲压出平坦展开的接触元件20或套筒部件30。接触元件20的展开件在此时与带材的支承条40保持连接。因此,冲压出的接触元件20为了大批量生产适合自动化的横向系带地(quergegurtet)与用作原材料的带材上仍保留的支承条40保持连接,以及可以此适合机械加工的状态发送给用户,在那里进行真正的插接装配。在冲压后,由Cu-Sn合金组成的带材在制造的工艺过程中表面电镀调质处理。在这方面例如作为粘合层首先施加一Ni层,接着施加一Au层和必要时一覆盖保护的Sn层。然后由接触元件20的展开件在接触零件10的连接区11向上弯曲成连接片21用于与要连接的导体的除去绝缘的部分挤压接触,以及向上弯曲成夹紧连接的连接片22用于图中未表示的电导体的绝缘部分。在接触零件10的接触区12,接触元件20的展开件卷成插座部分23。在接触元件20上成形沿径向扩展的区段24和25,它们与装在插头部分承接接触零件20的绝缘体上的锁止元件在工作上连接,以固定接触零件10在绝缘体承接孔内的位置。第一个沿径向扩展的区段24比沿轴向与之相隔间距的第二个沿径向扩展的区段25有较小的直径。因此,此接触零件10可使用于不同尺寸的绝缘体。接触元件20的插座部分23设计为开有平行于接触零件10中心线13亦即沿插接方向P的槽,从而有多个隔板状肋片26。在接触元件20的插接侧端部,插座部分23有一对设计为槽状的扭转切口,它们的功能下面还要详细说明。套筒部件30同样由平的材料卷成以及有两个相对置的端侧端部31和32。在对接边成形有成对的互相匹配的锁舌33和锁槽34,它们在卷成圆柱形套筒部件30时形状封闭地互相啮合。套筒部件30在其端部31和32还有固定槽35和36,它们的功能同样在下面详细说明。
现在按图1在第一个所表示的工艺步骤中套筒部件30从插接侧的端部那里套在接触元件20的插座部分23上,并定位为使肋片26被套筒部件30覆盖。
然后按图2在已定位的套筒部件30上冲压出一个沿周向延伸防止径向扩张的缩窄(缩颈)37。在套筒部件30内的缩窄37用作肋片26沿径向向外方向偏移的止挡并由此防止肋片过度扩张和因而防止损失对于与***的触针建立接触所必要的弹性特性。此外,这种缩窄有加工技术方面的优点,即,在进一步的工艺步骤中套筒部件30不再会从接触零件10的接触元件20上滑落和由此造成遗失。
套筒部件30在其防止沿径向张大的缩窄37处于肋片26中央时的轴向位置下,套筒部件30将其在连接侧的端部31通过在固定槽35处激光焊在接触元件20的套筒部件23上锁止。通过在图3中表示的工艺步骤,套筒部件30在接触元件20上的位置已固定。
在按图4的工艺步骤中,一个图中未表示的扭转工具的扭转部分被置于与在插座部分23插接侧端部上的扭转切口27啮合,以便扭转插座部分23。为此,接触元件20在肋片26所在区域之外在连接侧防止扭转以及在插接侧绕中心线13沿旋转方向T扭转一个可预定的角度,在图示的例子中为90°。在这种情况下肋片26弧形地朝中心线13的方向曲拱,所以肋片26区域成形为笼型结构,它与单壳式双曲面的形状贴近。在扭转时,套筒部件30按有利的方式起导引装置的作用并防止在扭转过程中插座部分23歪斜或纵向弯曲。成弧形的肋片26在图4中为了简化起见仅示意地表示。通过选择扭转角,可以调整肋片26曲拱的程度及其防止沿径向向外方向偏移的弹性系数。另一些规定的参数包括肋片26的材料以及尺寸。
与先有技术的教导不同,经扭转的接触元件20,与所实施的扭转究竟是全弹性或已经部分塑性无关,保持在此状态,并通过套筒部件在其固定槽36处激光焊在插座部分23上锁止。由此正好获得肋片26在扭转过程已调整好的机械特性。这些特性可以在预先试验中简单地确定。在保护套筒部件30下面,向内曲拱的肋片26构成许多接触面,在这些接触面处,接触零件10的插座部分23与一个图中没有表示的***插座部分23内的触针之间建立电接触。在触针***插座部分23内时,肋片26沿径向向外偏移,所以它们基于其弹性复位力以一个规定的接触压力紧压在触针上。为避免通过过大的径向偏移导致肋片26的过度膨胀扩张,借助在套筒部件30内侧防张大的缩窄的环形隆凸来限制肋片26的弹性行程。
应当指出,沿周向延伸的防止径向扩张的缩窄37的冲压也可以在套筒部件30锁止后进行。该冲压同样也并不取决于所述套筒部件30两个端部31、32中的哪一个在插座部分23扭转前首先锁止。

Claims (7)

1.一种制造用于可拆式电插塞连接的导电接触零件(10)的方法,其中,提供一个包括一个部分纵向开槽的插座部分(23)的接触元件(20),该插座部分(23)有沿其圆周分布设置的肋片(26),以及提供一个可围绕所述插座部分(23)和可覆盖其肋片(26)的带有两个相对置的端侧端部(31、32)的套筒部件(30),其特征为:所述套筒部件(30)大体同轴于所述插座部分(23)这样来设置和定位,即,使它覆盖所述插座部分(23)的肋片(26),并且使已完成定位的所述套筒部件(30)的两个端部(31、32)之一锁止在所述插座部分(23)上;所述插座部分(23)自身围绕其中心线(13)这样弹性地扭转,即,使所述肋片(26)弧形地朝向所述中心线(13)方向曲拱;以及,所述套筒部件(30)的两个端部(32、31)中的另一个在所述克服肋片(26)的弹性复位力保持扭转的插座部分(23)上锁止。
2.按照权利要求1所述的方法,其特征为:所述套筒部件(30)在所述插座部分(23)上的锁止通过机械卡锁实现。
3.按照权利要求1所述的方法,其特征为:所述套筒部件(30)在所述插座部分(23)上的锁止通过激光焊实现。
4.按照权利要求1至3之一所述的方法,其特征为:在已定位的所述套筒部件(30)上冲压出一个沿周向延伸的防扩张径向缩颈(37)。
5.按照权利要求1至4之一所述的方法,其特征为:在所述接触元件(20)上成型出至少一个沿径向扩展的区段(24、25)。
6.按照权利要求1至5之一所述的方法,其特征为:按一定的划分距离重复地由一带材冲压出平面展开的接触元件(20)以及必要时还冲压出平面展开的套筒部件(30),其中,该展开件与该带材的一个支承条(40)保持连接;对所冲压出的展开件表面进行调质处理;以及,通过滚卷该展开件的插座部分(23)和向上弯曲其连接片(21、22)部分成型出所述接触元件(20),必要时还通过滚卷来成型出所述套筒部件(30)。
7.按照权利要求6所述的方法,其特征为:在所述展开的套筒部件(30)上彼此配对地成型出互相匹配的锁舌(33)和锁槽(34),其中,在滚卷所述展开的套筒部件(30)时,所述锁舌(33)形状封闭连接地啮合在与之相配的所述锁槽(34)内。
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