EP2715874B1 - Plug bridge with closed folding pins - Google Patents

Plug bridge with closed folding pins Download PDF

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Publication number
EP2715874B1
EP2715874B1 EP12723471.4A EP12723471A EP2715874B1 EP 2715874 B1 EP2715874 B1 EP 2715874B1 EP 12723471 A EP12723471 A EP 12723471A EP 2715874 B1 EP2715874 B1 EP 2715874B1
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EP
European Patent Office
Prior art keywords
phase
neutral
conductor pin
pin
pins
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Not-in-force
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EP12723471.4A
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German (de)
French (fr)
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EP2715874A1 (en
Inventor
Roland Trattner
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Taller GmbH
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Taller GmbH
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/46—Bases; Cases
    • H01R13/502—Bases; Cases composed of different pieces
    • H01R13/504—Bases; Cases composed of different pieces different pieces being moulded, cemented, welded, e.g. ultrasonic, or swaged together
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R24/00—Two-part coupling devices, or either of their cooperating parts, characterised by their overall structure
    • H01R24/28—Coupling parts carrying pins, blades or analogous contacts and secured only to wire or cable
    • H01R24/30—Coupling parts carrying pins, blades or analogous contacts and secured only to wire or cable with additional earth or shield contacts
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R2103/00—Two poles

Definitions

  • the invention relates to a connector bridge for an electrical appliance plug for connecting electrical appliances, in particular household appliances, to a socket of an AC mains, wherein the appliance plug is formed as a unit by connected to the tail of a three-wire connection cable for the device, molded in an injection mold connector bridge, the In turn, the phase, neutral and Erdleiterstatt in their cross section corresponding openings of the insulator in one and the same operation with the injection of the insulator with a different structure is constructed of a dimensionally stable insulating body for receiving and fixing a respective rectangular phase conductor pin, neutral conductor and Erdleiterstattes.
  • phase, neutral and Erdleiter are injected, wherein the phase, neutral and Erdleiterstatt over the plug bridge and the device plug protrude far enough to be inserted into the socket, the phase, neutral and Erdleiter forest each Einf Have chamfers, wherein the phase and Nulleiterstatt each have a isolierEffe insulation and wherein the phase, neutral and Erdleiter forest is executed in each case as FaltX pulled from an initially flat punched metal sheet into its final spatial form, unfolded and during the injection process of Insulating body is filled in its cavities and interstices with plastic so that after the injection process of the phase, zero or Erdleiterstatt has its final contour.
  • the special feature of this plug is that the Erdleiter 202 serves as a mechanical unlocking when plugging the device plug into the socket of the power or power supply network.
  • This Erdleiter forest is longer than the phase and Nulleiter foreste, and only with the insertion of this Erdleiter forestes, it is possible that the other two pins can be inserted functionally.
  • phase conductors and neutral conductors in the United Kingdom are rectangular 3.98 x 6.35 x 17.7 mm (+/- 0.08 x 0.13 x 0.5 mm), with the connector side 9.35 mm (+/- 0.15 mm) must be isolated.
  • the earth conductor pin is to be mounted in the middle over the two other pins at a distance of 22.23 mm (+/- 0.13 mm).
  • This pen is also rectangular in size, measuring 3.975 x 7.93 x 22.73 mm (+/- 0.08 x 0.13 x 0.5 mm), but without insulation.
  • connection cable for the device to be connected on the one hand and the connection or plug pins for the socket are encapsulated ,
  • the cable can not be disconnected from the plug.
  • connection aids facilitate the secure connection of the cable.
  • the plug pins can be connected on the plug side both via crimp and rivet contacts.
  • jumper bridges are installed in large quantities in the production of device connectors. Since relatively small price differences already have a significant impact on competitiveness in the fiercely contested market, developments to reduce costs or material in this technical field are particularly important.
  • a pin is described, which is formed from a rolled sheet metal strip.
  • the interior of the connector pin can also be filled with plastic. In this way, only round pin shapes can be made.
  • Object of the present invention is in contrast to improve a generic jumper of the type described above with the simplest technical means uncomplicated and inexpensive to go that can continue to be saved in the production of the jumper to a considerable extent material, the pins in the socket-side contacting however, have no plastic deposits.
  • the folding pins of the DE 10 2009 049 369 A1 are made of a rectangular stamped part and unfolded so that the two narrow side edges (as rivet or crimp barrel and locking edge) lock on the plug side.
  • the insertion bevels are unfolded from the middle of the stamped part. This inevitably creates a gap on the narrow side of the unfolded pen, which is then filled with plastic.
  • the punched part is locked positively and non-positively at the narrow sides during unfolding.
  • the cable-side connecting sleeve is punched out of the center of the stamped part and unfolded, instead of being unfolded from the end of the strip. Due to the fact that the short side edges of the rectangular stamped part form the insertion bevels, it is possible to form all surfaces in the socket-side contact area from the stamped part and thus avoid plastic deposits on all surfaces which have contact with live parts of the socket.
  • the plug-in bridge according to the invention is characterized in that the flat stamped part, from which the phase, zero or earth conductor pin is pulled and unfolded into its final spatial form, is punched out and unfolded into a long metal sheet twice the width of the phase, Zero or Erdleiterstatts is. Long metal sheets can thus be placed in the processing machine. This simplifies production and handling. Since the metal sheets have the exact width twice the length of the respective pins, the amount of "metal waste" in production is drastically reduced.
  • a further embodiment is characterized in that a cone-shaped hole is punched into the web with a punch that tapers in the front, which forms a rivet after unfolding.
  • the rivet must not be soldered, welded or screwed, but is integrated in the folding pin.
  • a development of the previous embodiments is characterized in that from the remaining between the punched sheet metal strips sheet metal pieces phase, zero or Erdleiterstatt be unfolded. This further reduces the amount of unused material and makes production more effective and faster.
  • phase, zero or Erdleiter at the folds on noses and cutouts, wherein when folded, the noses come to lie deformed in the cutouts and thus allow a positive and non-positive connection. This allows an even more stable locking of the two halves of the folding pin.
  • oblong holes are punched from the flat stamped part for the phase conductor pin or the neutral conductor mirror-symmetrical to the longitudinal axis, which are positioned after unfolding on the wide sides of the rectangular phase conductor pin or the neutral conductor pin and which later during encapsulation allow the plastic to flow in a particularly optimal manner around the points to be insulated.
  • Another beneficial effect of this design is additional material savings.
  • phase conductor pin and the neutral conductor pin have lateral cutouts in their connecting cable-side section, which receive the insulating plastic according to BS 1363 during the casting process.
  • a stamping preferably from 0.5 mm to 0.3 mm exhibit.
  • phase, neutral and Erdleiter each having a rivet at its connection cable end.
  • the current-carrying contacts can be riveted on the plug side in a simple manner.
  • the flat stampings for the phase, neutral and Erdleiterstatt of electrically conductive material preferably brass sheet, which is preferred because of its good electrical conductivity and mechanical stability properties and its relatively low tendency to corrosion as a starting material for the current-carrying parts.
  • an embodiment is preferred, which is characterized in that an electrical fuse is provided against excessive current flow. This is prescribed in the aforementioned British standard BS 1363. Therefore, this embodiment is mandatory for jumper connectors intended for use in the UK.
  • Fig. 1 shows a three-dimensional representation of an embodiment of a power supply connector 1 with inventive connector bridge with an insulating body 2 made of electrically insulating material and with plug pins 3 a, b, c of electrically conductive material.
  • the contact surface of the Erdleiterstatts 3a includes the longitudinal sides of the pin in its entire length.
  • the contact surfaces of the Phasertleiterstatts 3b and the neutral conductor pin 3c are approximately halfway surrounded by an insulation 4 . All surfaces which could have contact on the plug side with live parts are made of metal, in particular the insertion bevels 5 .
  • the plug pins 3 a, b, c according to the invention have no plastic surfaces where the current-carrying mating contacts of the socket with the plug pins 3 a, b, c have contact.
  • the plug pins 3a, b, c have at the seams 6 lugs 7a and corresponding recesses 7b . This allows a particularly strong positive and non-positive locking.
  • a holder 8 is provided for a backup, which can not reach when plugged device plug.
  • FIG. 2 the structure of a power supply connector 1 with a connector bridge according to the invention again clarified as partially truncated representation.
  • the conductor rails 10 lead the current to the corresponding crimp sleeves 11 ( FIG. Fig. 3 ) for connecting the wires of a power cord.
  • Fig. 4 shows a spatial view of the unfolded in the spatial shape blank of a phase or neutral conductor 3 b, c.
  • the contact surfaces on the plug-side end of the phase or neutral conductor 3 b, c are made entirely of metal.
  • the lugs 7a and 7b recesses into each other to lock the folding pin positive and non-positive.
  • the British standard BS1363 prescribes for the phase or Nulleiterstatt 3 b, c that plug side 9.35 mm (+/- 0.15 mm) insulation 4 (indicated by dashed lines) must be arranged. So that the insulation 4 in one Operation with the encapsulation of the insulating body 2 ( Fig.
  • the unfolded stamped part of the phase conductor or neutral conductor 3 b, c has elongated holes 12 . Through these slots 12, the injection molding compound can better get into the interior of the phase or Nulleiterstatts 3 b, c. Side cutouts 13 and stampings 14 help to make the insulation 4 clean and to obtain the prescribed contours. Due to the illustrated construction, the injection-molding compound can flow into the interior of the phase or neutral conductor 3 b, c, but no plastic comes into contact with the form-fitting and force-locked metal surface of those surfaces which come into contact with the current-carrying parts of the socket with these live parts.
  • the Erdleiter busy 3a shown in Fig. 5 Although it does not come into contact with permanently live parts of the socket, it may have to dissipate static charges or fault currents if necessary. For this reason, the British authorities also require from this pin a closed metal shell without plastic inclusions.
  • Fig. 5 illustrated Erdleiterstatt 3a, including the insertion bevels 5, all around metal surfaces.
  • the lugs 7a engage in the recesses 7b and close the Erdleiterstatt 3a along the fold seam 6 positive and non-positive.
  • Filling holes 15 later from the insulating body 2 ( Fig. 1 ), guarantee that the Injection molding compound can get into the interior of the Erdleiter forestss 3a, giving it extra stability.
  • Fig. 6 shows the spatial representation of the punching and Auffaltungsproszesses a Erdleiterstatts 3a according to the invention.
  • the filling holes 15 are first punched out of a long metal sheet 16, preferably made of sheet brass.
  • the metal sheet 16 has twice the width B of the length L of the future Erdleiterstatts 3a.
  • the gaps 17 between the Erdleiterstatten 3 a are punched out.
  • the gaps 17 are kept as small as possible for economic and environmental reasons, in order to reduce the produced metal waste.
  • the outer contours of Erdleitererlixs 3a with the lugs 7a and recesses 7b, which mesh with each other when unfolding are now already clearly visible.
  • the rivet sleeve 9 is now partially punched out of the remaining web 18 , partially pressed.
  • the phase or Nulleiterstatt 3b, 3c are unfolded analogously, instead of the filling holes 15, the slots 12 are punched and additionally the cutouts 13 and stampings 14 are punched or stamped.

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  • Connector Housings Or Holding Contact Members (AREA)
  • Details Of Connecting Devices For Male And Female Coupling (AREA)
  • Manufacturing Of Electrical Connectors (AREA)

Description

Hintergrund der ErfindungBackground of the invention

Die Erfindung betrifft eine Steckerbrücke für einen elektrischen Gerätestecker zum Anschließen elektrischer Geräte, insbesondere Haushaltsgeräte, an eine Steckdose eines Wechselstromnetzes, wobei der Gerätestecker als Einheit durch die mit dem Endstück eines dreiadrigen Anschlusskabels für das Gerät verbundene, in einer Spritzform umspritzte Steckerbrücke gebildet ist, die ihrerseits aus einem formstabilen Isolierkörper zur Aufnahme und Fixierung eines jeweils rechteckigen Phasenleiterstiftes, Nullleiterstiftes und Erdleiterstiftes aufgebaut ist, wobei der Phasen-, Null- und Erdleiterstift in ihrem Querschnitt entsprechenden Durchbrüchen des Isolierkörpers in ein- und demselben Arbeitsgang mit dem Spritzen des Isolierkörpers mit an- bzw. eingespritzt sind, wobei der Phasen-, Null- und Erdleiterstift gegenüber der Steckerbrücke und dem Gerätestecker weit genug vorstehen, um in die Steckdose eingeführt zu werden, wobei der Phasen-, Null- und Erdleiterstift jeweils Einführschrägen aufweisen, wobei der Phasen- und Nulleiterstift jeweils eine isolierkörperseitige Isolierung aufweisen und wobei der Phasen-, Null- und Erdleiterstift jeweils als Faltstift ausgeführt ist, der aus einem zunächst flachen Stanzteil aus Metallblech in seine endgültige Raumform gezogen, aufgefaltet und beim Spritzprozess des Isolierkörpers in seinen Hohl- und Zwischenräumen mit Kunststoff derart aufgefüllt ist, dass nach dem Spritzprozess der Phasen-, Null- bzw. Erdleiterstift seine endgültige Kontur besitzt.The invention relates to a connector bridge for an electrical appliance plug for connecting electrical appliances, in particular household appliances, to a socket of an AC mains, wherein the appliance plug is formed as a unit by connected to the tail of a three-wire connection cable for the device, molded in an injection mold connector bridge, the In turn, the phase, neutral and Erdleiterstift in their cross section corresponding openings of the insulator in one and the same operation with the injection of the insulator with a different structure is constructed of a dimensionally stable insulating body for receiving and fixing a respective rectangular phase conductor pin, neutral conductor and Erdleiterstiftes. are injected, wherein the phase, neutral and Erdleiterstift over the plug bridge and the device plug protrude far enough to be inserted into the socket, the phase, neutral and Erdleiterstift each Einf Have chamfers, wherein the phase and Nulleiterstift each have a isolierkörperseitige insulation and wherein the phase, neutral and Erdleiterstift is executed in each case as Faltstift pulled from an initially flat punched metal sheet into its final spatial form, unfolded and during the injection process of Insulating body is filled in its cavities and interstices with plastic so that after the injection process of the phase, zero or Erdleiterstift has its final contour.

Eine derartige Steckerbrücke entsprechend dem Oberbegriff von Anspruch 1 ist beispielsweise beschrieben in DE 10 2009 049 369 A1 .Such a connector bridge according to the preamble of claim 1 is described for example in DE 10 2009 049 369 A1 ,

Sie werden insbesondere in Großbritannien und im englischsprachigen Raum verwendet. Das besondere Merkmal dieser Stecker liegt darin, dass der Erdleiterstift als mechanische Entriegelung beim Einstecken des Gerätesteckers in die Steckdose des Strom- bzw. Spannungsversorgungsnetzes dient. Dieser Erdleiterstift ist länger ausgebildet als die Phasen- und Nulleiterstifte, und erst mit dem Einstecken dieses Erdleiterstiftes ist es möglich, dass auch die beiden anderen Stifte funktionsgerecht eingeführt werden können.They are used in particular in the UK and in English-speaking countries. The special feature of this plug is that the Erdleiterstift serves as a mechanical unlocking when plugging the device plug into the socket of the power or power supply network. This Erdleiterstift is longer than the phase and Nulleiterstifte, and only with the insertion of this Erdleiterstiftes, it is possible that the other two pins can be inserted functionally.

Gemäß der britischen Norm BS 1363 sind in Großbritannien Phasenleiter- und Nullleiter rechteckig mit den Maßen 3,98 x 6,35 x 17,7 mm (+/- 0,08 x 0,13 x 0,5 mm) auszuführen, wobei steckerseitig 9,35 mm (+/- 0,15 mm) isoliert sein müssen. Der Erdleiterstift ist in der Mitte über den beiden anderen Stiften anzubringen in einem Abstand von 22,23 mm (+/- 0,13 mm). Dieser Stift ist ebenfalls rechteckig auszuführen, in den Maßen 3,975 x 7,93 x 22,73 mm (+/- 0,08 x 0,13 x 0,5 mm) jedoch ohne Isolierung.According to British standard BS 1363, phase conductors and neutral conductors in the United Kingdom are rectangular 3.98 x 6.35 x 17.7 mm (+/- 0.08 x 0.13 x 0.5 mm), with the connector side 9.35 mm (+/- 0.15 mm) must be isolated. The earth conductor pin is to be mounted in the middle over the two other pins at a distance of 22.23 mm (+/- 0.13 mm). This pen is also rectangular in size, measuring 3.975 x 7.93 x 22.73 mm (+/- 0.08 x 0.13 x 0.5 mm), but without insulation.

Zusätzlich zu der oben beschriebenen mechanischen Sicherung bestehen die heutigen Gerätestecker aus Gründen der elektrischen Sicherheit aus gegossenen bzw. gespritzten Steckkörpern, in deren Inneren die elektrische Verbindung zwischen dem Anschlusskabel für das anzuschließende Gerät einerseits und den Anschluss- bzw. Steckerstiften für die Steckdose andererseits eingekapselt sind. Im Allgemeinen kann das Kabel nicht vom Stecker getrennt werden. Verschiedenartige Anschlusshilfen erleichtern das sichere Anschließen der Leitungskabel. Die Steckstifte können steckerseitig sowohl über Crimp- als auch Nietkontakte angeschlossen werden.In addition to the mechanical fuse described above, the current device connectors for reasons of electrical safety made of molded or injection-molded plug bodies, in the interior of the electrical connection between the connection cable for the device to be connected on the one hand and the connection or plug pins for the socket are encapsulated , In general, the cable can not be disconnected from the plug. Various connection aids facilitate the secure connection of the cable. The plug pins can be connected on the plug side both via crimp and rivet contacts.

Diese und ähnliche Steckerbrücken werden bei der Produktion von Gerätesteckern in großen Stückzahlen verbaut. Da sich auf dem stark umkämpften Markt bereits relativ kleine Preisunterschiede erheblich auf die Konkurrenzfähigkeit auswirken, haben Entwicklungen zur Einsparung von Kosten bzw. Material in diesem technischen Gebiet einen besonders großen Stellenwert.These and similar jumper bridges are installed in large quantities in the production of device connectors. Since relatively small price differences already have a significant impact on competitiveness in the fiercely contested market, developments to reduce costs or material in this technical field are particularly important.

So wird in GB 2 092 836 A ein Stecker beschrieben, der aus Stanzteilen gefaltete Steckerstifte verwendet. Dies führt zweifellos zu einer erheblichen Materialeinsparung. Es handelt sich hierbei jedoch um ein Montagesystem, bei dem die Steckerstifte und steckerseitigen Kontakte nicht, wie heute üblich, im Gussverfahren eingekapselt werden. Dadurch ist bei dieser Konstruktion, im Gegensatz zu modernen Steckersystemen, nicht sichergestellt, dass einzelne Leitungsdrähte aus dem Gehäuseinneren nach außen ragen. Darüber hinaus sind diese Faltstifte aufgrund ihrer Bauweise mechanisch instabil, des Weiteren kann durch die großen Hohlräume Feuchtigkeit in das Steckerinnere gelangen. Hinzukommt, dass dieses System aufgrund seiner Bauweise nicht für die Massenproduktion geeignet ist, da sich hier auch die in oben genannter Norm BS 1363 vorgeschriebene Teilisolierung des Phasenleiter- und Nullleiters nicht auf einfache Weise realisieren lässt. Aus diesem Grunde muss die in GB 2 092 836 A beschriebene Konstruktion als überholt betrachtet werden, so dass der Fachmann auf dem einschlägigen Gebiet hier keine Anregungen für Verbesserungen des aktuellen Steckersystems suchen würde.So will in GB 2 092 836 A a connector described which uses punched parts folded pins. This undoubtedly leads to considerable material savings. However, this is a mounting system in which the connector pins and plug-side contacts are not, as is common today encapsulated in the casting process. As a result, in contrast to modern plug systems, this construction does not ensure that individual lead wires protrude out of the housing interior to the outside. In addition, these folding pins are mechanically unstable due to their design, furthermore can get through the large cavities moisture in the plug inside. In addition, due to its design, this system is not suitable for mass production, since the partial insulation of the phase conductor and neutral conductor prescribed in the abovementioned BS 1363 standard can not be realized in a simple manner. For this reason, the in GB 2 092 836 A described construction are considered obsolete, so that those skilled in the relevant field would not seek any suggestions for improvements of the current connector system.

Ausgehend von normgerechten Konstruktionen, wie sie in DE 198 01 896 C1 und DE 100 51 348 C2 beschrieben sind, wurde unter anderem versucht, durch das Anfräsen und mit Kunststoff auffüllen der ansonsten massiven Steckerstifte, Material einzusparen, wie etwa in DE 10 2007 009 422 A1 gezeigt. Diese Methode der Materialeinsparung wirkt sich jedoch wegen der aufwändigen Bearbeitung nachteilig auf die Produktionsgeschwindigkeit und damit letztlich auch auf die Herstellungskosten aus. Während für die massiven Steckerstifte Produktionszahlen von etwa 80 bis 100 Stück pro Minute erreicht werden, sind es für die gefrästen Steckerstifte nur noch 60 bis 80 Stück pro Minute.Starting from standardized constructions, as in DE 198 01 896 C1 and DE 100 51 348 C2 have been described, among other things, tried by the milling and plastic fill the otherwise massive pins, material savings, such as in DE 10 2007 009 422 A1 shown. However, this method of material saving has a disadvantageous effect on the production speed and thus ultimately on the production costs because of the complex processing. While production figures of about 80 to 100 pieces per minute are achieved for the massive connector pins, only 60 to 80 pieces per minute are needed for the milled connector pins.

In DE 43 14 195 A1 wird ein Steckerstift beschrieben, der aus einem gerollten Blechstreifen geformt ist. Das Innere des Steckerstifts kann auch mit Kunststoff ausgegossen werden. Auf diese Weise können aber nur runde Stiftformen hergestellt werden.In DE 43 14 195 A1 a pin is described, which is formed from a rolled sheet metal strip. The interior of the connector pin can also be filled with plastic. In this way, only round pin shapes can be made.

In der DE 2009 049 369 A1 ist eine Steckerbrücke mit Faltstiften beschrieben, die beim Umspritzen ihre endgültige äußere Form erhalten. Insbesondere wird hier viel Material eingespart. Allerdings weisen die Einführschrägen der Steckerstifte bedingt durch den Faltungsprozess an den Schmalseiten der Stifte Lücken auf, die beim Umspritzen dann mit Kunststoff aufgefüllt werden. Derartige Kunststoffeinlagerungen können sich aber in Extremsituationen bei hohen Strömen und hohen Temperaturen als nachteilig erweisen. Zudem ist an diesen Stellen auch keine Kontaktierung möglich. Daher werden solche Steckerstifte von den Behörden in Großbritannien nicht mehr zugelassen.In the DE 2009 049 369 A1 is described a connector bridge with folding pins, which receive their final outer shape during encapsulation. In particular, much material is saved here. However, due to the folding process, the insertion bevels of the plug pins on the narrow sides of the pins have gaps which are then filled with plastic during the encapsulation. Such plastic deposits may prove to be disadvantageous in extreme situations at high currents and high temperatures. In addition, no contacting is possible at these locations. Therefore, such pins are no longer approved by the authorities in the UK.

Aufgabe der ErfindungObject of the invention

Aufgabe der vorliegenden Erfindung ist es demgegenüber, eine gattungsgemäße Steckerbrücke der eingangs beschriebenen Art mit möglichst einfachen technischen Mitteln unaufwändig und kostengünstig dahin gehend zu verbessern, dass weiterhin bei der Herstellung der Steckerbrücke in erheblichem Maße Material eingespart werden kann, die Steckerstifte im Bereich der steckdosenseitigen Kontaktierung jedoch keine Kunststoffeinlagerungen aufweisen.Object of the present invention is in contrast to improve a generic jumper of the type described above with the simplest technical means uncomplicated and inexpensive to go that can continue to be saved in the production of the jumper to a considerable extent material, the pins in the socket-side contacting however, have no plastic deposits.

Kurze Beschreibung der ErfindungBrief description of the invention

Diese Aufgabe wird erfindungsgemäß auf ebenso überraschend einfache wie wirkungsvolle Weise dadurch gelöst, dass nach Umspritzen der Steckerbrücke steckdosenseitig alle Oberflächen des so entstandenen Phasen-, Null- bzw. Erdleiterstifts, inklusive der Einführschrägen, zumindest bis zur isolierkörperseitigen Isolierung aus dem Metallblech bestehen Durch die Herstellung aus einem Stanzteil wird gegenüber der massiven Bauweise in erheblichem Maße Material eingespart. Aufgrund der maschinellen Faltung und der dafür verfügbaren Maschinen kann zudem auf diese Weise die Produktionsgeschwindigkeit deutlich erhöht werden. Die notwendige Stabilität und Hohlraumversiegelung der Faltstifte erfolgt hier auf besonders einfache und kostengünstige Weise in einem Schritt mit dem Gussverfahren, mit dem der gesamte Stecker ohnehin eingegossen wird. Gegenüber Vollmetallstiften wird so 60% Material eingespart und somit ein Beitrag zur von der Europäischen Kommission geforderten effizienten Ressourcennutzung geleistet.This object is achieved in a surprisingly simple as well as effective way in that after encapsulation of the connector bridge all the surfaces of the resulting phase, zero or Erdleiterstifts, including the insertion bevels, at least insierkörperseitigen insulation from the metal sheet socket side by the production of a stamped part is saved over the massive construction material to a considerable extent. Due to the mechanical folding and the machines available for this purpose, the production speed can also be significantly increased in this way. The necessary stability and cavity sealing of the folding pins is done here in a particularly simple and cost-effective manner in one step with the casting process, with which the entire plug is poured anyway. Compared to solid metal pencils, this saves 60% of material, thus contributing to the efficient use of resources demanded by the European Commission.

Die Faltstifte der DE 10 2009 049 369 A1 werden aus einem rechteckigen Stanzteil gefertigt und so aufgefaltet, dass die beiden schmalen Seitenkanten (als Niet- bzw. Crimphülse und Verriegelungkante) steckerseitig verriegeln. Die Einführschrägen werden aus der Mitte des Stanzteils aufgefaltet. Dabei entsteht unweigerlich eine Lücke auf der Schmalseite des aufgefalteten Stifts, die dann mit Kunststoff gefüllt wird.The folding pins of the DE 10 2009 049 369 A1 are made of a rectangular stamped part and unfolded so that the two narrow side edges (as rivet or crimp barrel and locking edge) lock on the plug side. The insertion bevels are unfolded from the middle of the stamped part. This inevitably creates a gap on the narrow side of the unfolded pen, which is then filled with plastic.

Bei der vorliegenden Erfindung wird das Stanzteil beim Auffalten jedoch an den Schmalseiten form- und kraftschlüssig verriegelt. Die kabelseitige Anschlusshülse wird dabei aus der Mitte des Stanzteils eingestanzt und aufgefaltet, statt aus dem Ende des Streifens aufgefaltet zu werden. Dadurch, dass die kurzen Seitenkanten des rechteckigen Stanzteils die Einführschrägen bilden, ist es möglich, alle Oberflächen im steckdosenseitigen Kontaktbereich aus dem Stanzteil zu bilden und somit Kunststoffeinlagerungen an allen Flächen, die Kontakt zu stromführenden Teilen der Steckdose haben, zu vermeiden.In the present invention, however, the punched part is locked positively and non-positively at the narrow sides during unfolding. The cable-side connecting sleeve is punched out of the center of the stamped part and unfolded, instead of being unfolded from the end of the strip. Due to the fact that the short side edges of the rectangular stamped part form the insertion bevels, it is possible to form all surfaces in the socket-side contact area from the stamped part and thus avoid plastic deposits on all surfaces which have contact with live parts of the socket.

Durch die Art der Auffaltung ist es auch nunmehr möglich, die Stanzteile direkt aus einem langen, rechteckigen Blech zu fertigen. Bisher mussten die Stanzteile erst ausgestanzt und danach einzeln aufgefaltet werden. Dies ist durch die neue Faltungsmethode jetzt in einem Arbeitsgang möglich. Eine Produktion von 320 bis 360 Teilen pro Minute erscheint machbar, gegenüber 70-80 Teilen pro Minute bei Vollmaterialstiften. Das bedeutet bei gleicher Stückzahl eine Reduzierung der Produktionszeit um etwa 75%.Due to the type of unfolding, it is now possible to produce the stamped parts directly from a long, rectangular sheet metal. So far, the stamped parts had only punched out and then unfolded individually. This is now possible in a single operation thanks to the new folding method. A production of 320 to 360 parts per minute seems feasible compared to 70-80 parts per minute for solid material pens. This means a reduction in production time of about 75% for the same number of pieces.

Die erfindungsgemäße Steckerbrücke ist dadurch gekennzeichnet, dass das flache Stanzteil, aus dem der Phasen-, Null- bzw. Erdleiterstifts in seine endgültige Raumform gezogen und aufgefaltet ist, vor dem Ausstanzen und Auffalten ein langes Metallblech von der Breite der doppelten Länge des Phasen-, Null- bzw. Erdleiterstifts ist. Lange Metallbleche können so in die Verarbeitungsmaschine gegeben werden. Dies vereinfacht die Produktion und Handhabung. Da die Metallbleche die exakte Breite der doppelten Länge der jeweiligen Stifte haben, wird die Menge an "Metallabfall" bei der Produktion drastisch reduziert.The plug-in bridge according to the invention is characterized in that the flat stamped part, from which the phase, zero or earth conductor pin is pulled and unfolded into its final spatial form, is punched out and unfolded into a long metal sheet twice the width of the phase, Zero or Erdleiterstifts is. Long metal sheets can thus be placed in the processing machine. This simplifies production and handling. Since the metal sheets have the exact width twice the length of the respective pins, the amount of "metal waste" in production is drastically reduced.

Aus dem langen Metallblech wird eine Vielzahl von Blechstreifen herausgestanzt, wobei in der Mitte der Querachse ein Steg verbleibt, welcher nach dem Auffalten das steckerseitige Ende des Phasen-, Null- bzw. Erdleiterstifts bildet. Nicht die Faltstifte selbst werden herausgestanzt, sondern die Zwischenräume. In der Mitte verbleibt ein Steg, von dem aus sich flügelartig die "zukünftigen" Stiftkörper erstrecken. Erst nach dem Auffalten der Stifte wird der Steg durchtrennt und entsteht somit ein separater Stift. Dadurch wird weiter die Menge an nicht verwendetem Material reduziert und die Produktion effektiver und schneller gemacht.From the long metal sheet, a plurality of sheet metal strips is punched out, wherein in the middle of the transverse axis a web remains, which forms after unfolding the plug-side end of the phase, neutral or Erdleiterstifts. Not the folding pins themselves are punched out, but the gaps. In the middle of a bridge remains, from which wing-like "future" pen body extend. Only after the unfolding of the pins, the bridge is severed and thus creates a separate pin. This further reduces the amount of unused material and makes production more effective and faster.

Eine weitere Ausführungsform ist dadurch gekennzeichnet, dass mit einer sich vorne verjüngenden Stanze ein konusförmiges Loch in den Steg gestanzt wird, welches nach dem Auffalten eine Niethülse bildet. Die Niethülse muss nicht angelötet, angeschweißt oder verschraubt werden, sondern ist im Faltstift integriert.A further embodiment is characterized in that a cone-shaped hole is punched into the web with a punch that tapers in the front, which forms a rivet after unfolding. The rivet must not be soldered, welded or screwed, but is integrated in the folding pin.

Eine Weiterbildung der vorherigen Ausführungsformen ist dadurch gekennzeichnet, dass aus den zwischen den herausgestanzten Blechstreifen verbliebenen Blechstücken Phasen-, Null- bzw. Erdleiterstift aufgefaltet werden. Dadurch wird weiter die Menge an nicht verwendetem Material reduziert und die Produktion effektiver und schneller gemacht.A development of the previous embodiments is characterized in that from the remaining between the punched sheet metal strips sheet metal pieces phase, zero or Erdleiterstift be unfolded. This further reduces the amount of unused material and makes production more effective and faster.

Bei einer weiteren vorteilhaften Ausführungsform weisen Phasen-, Null- bzw. Erdleiterstift an den Faltnähten Nasen und Ausschnitte auf, wobei beim Auffalten die Nasen in den Ausschnitten verformt zu liegen kommen und somit eine form- und kraftschlüssige Verbindung ermöglichen. Dies erlaubt eine noch stabilere Verriegelung der beiden Hälften des Faltstifts.In a further advantageous embodiment, phase, zero or Erdleiterstift at the folds on noses and cutouts, wherein when folded, the noses come to lie deformed in the cutouts and thus allow a positive and non-positive connection. This allows an even more stable locking of the two halves of the folding pin.

Vorteilhaft ist auch eine Ausführungsform, welche dadurch gekennzeichnet ist, dass aus dem flachen Stanzteil für den Phasenleiterstift oder den Nullleiterstift spiegelsymmetrisch zur Längsachse Langlöcher ausgestanzt werden, welche nach dem Auffalten an den breiten Seiten des rechteckigen Phasenleiterstifts oder des Nullleiterstifts positioniert sind und welche später beim Umspritzen den Kunststoff auf besonders optimale Weise um die zu isolierenden Stellen fließen lassen. Ein weiterer vorteilhafter Effekt dieser Ausführung ist eine zusätzliche Materialeinsparung.Also advantageous is an embodiment which is characterized in that oblong holes are punched from the flat stamped part for the phase conductor pin or the neutral conductor mirror-symmetrical to the longitudinal axis, which are positioned after unfolding on the wide sides of the rectangular phase conductor pin or the neutral conductor pin and which later during encapsulation allow the plastic to flow in a particularly optimal manner around the points to be insulated. Another beneficial effect of this design is additional material savings.

Eine weitere bevorzugte Ausführungsform ist dadurch gekennzeichnet, dass der Phasenleiterstift und der Nullleiterstift seitliche Ausschnitte in ihrem anschlusskabelseitigen Abschnitt aufweisen, welche beim Gussprozess den isolierenden Kunststoff gemäß BS 1363 aufnehmen.A further preferred embodiment is characterized in that the phase conductor pin and the neutral conductor pin have lateral cutouts in their connecting cable-side section, which receive the insulating plastic according to BS 1363 during the casting process.

Bevorzugt ist auch eine Ausführungsform der erfindungsgemäßen Steckerbrücke, bei welcher der Phasenleiterstift und der Nullleiterstift auf mindestens einer seitlichen Flanke eine Abprägung vorzugsweise von 0,5mm auf 0,3mm aufweisen. Dadurch wird der Herstellungsprozess der vorangehend erwähnten Teilisolierung noch weiter vereinfacht.Also preferred is an embodiment of the connector bridge according to the invention, in which the phase conductor pin and the neutral conductor pin on at least one lateral edge, a stamping preferably from 0.5 mm to 0.3 mm exhibit. As a result, the manufacturing process of the above-mentioned partial insulation is further simplified.

Vorteilhaft ist auch, wenn der Phasen-, Null- und Erdleiterstift jeweils an seinem anschlusskabelseitigen Ende einen Hohlniet aufweist. Mit einer solchen Ausführungsform lassen sich steckerseitig die stromführenden Kontakte auf einfache Weise vernieten.It is also advantageous if the phase, neutral and Erdleiterstift each having a rivet at its connection cable end. With such an embodiment, the current-carrying contacts can be riveted on the plug side in a simple manner.

Bei einer weiteren Ausführungsform bestehen die flachen Stanzteile für den Phasen-, Null- und Erdleiterstift aus elektrisch leitendem Material, vorzugsweise Messingblech, welches wegen seiner guten elektrischen Leitungs- und mechanischen Stabilitätseigenschaften sowie seiner relativ geringen Korrosionsneigung als Ausgangsmaterial für die Stromführenden Teile bevorzugt wird.In a further embodiment, the flat stampings for the phase, neutral and Erdleiterstift of electrically conductive material, preferably brass sheet, which is preferred because of its good electrical conductivity and mechanical stability properties and its relatively low tendency to corrosion as a starting material for the current-carrying parts.

Weiterhin wird eine Ausführungsform bevorzugt, welche dadurch gekennzeichnet ist, dass eine elektrische Sicherung gegen zu hohen Stromdurchfluss vorgesehen ist. Diese ist in der erwähnten britischen Norm BS 1363 vorgeschrieben. Daher ist diese Ausführungsform bei Steckerbrücken, die zum Einsatz in Großbritannien bestimmt sind, obligatorisch.Furthermore, an embodiment is preferred, which is characterized in that an electrical fuse is provided against excessive current flow. This is prescribed in the aforementioned British standard BS 1363. Therefore, this embodiment is mandatory for jumper connectors intended for use in the UK.

Weitere Vorteile der Erfindung ergeben sich aus der Beschreibung und der Zeichnung. Ebenso können die vorstehend genannten und die weiter aufgeführten Merkmale je für sich oder zu mehreren in beliebigen Kombinationen Verwendung finden. Die gezeigten und beschriebenen Ausführungsformen sind nicht als abschließende Aufzählung zu verstehen, sondern haben vielmehr beispielhaften Charakter für die Schilderung der Erfindung.Further advantages of the invention will become apparent from the description and the drawings. Likewise, the features mentioned above and those listed further can be used individually or in any combination. The embodiments shown and described are not to be understood as exhaustive enumeration, but rather have exemplary character for the description of the invention.

Zeichnung und detaillierte Beschreibung der ErfindungDrawing and detailed description of the invention

Es zeigen:

Fig. 1
eine räumliche Darstellung einer Ausführungsform eines Netzgerätesteckers mit erfindungsgemäßer Steckerbrücke;
Fig. 2
die teilweise aufgeschnittene räumliche Darstellung der Ausführungsform wie in Fig. 1;
Fig. 3
eine räumliche Darstellung einer Ausführungsform eines Netzgerätesteckers mit erfindungsgemäßer Steckerbrücke aus einem anderen Blickwinkel als Fig. 1;
Fig. 4
eine räumliche Ansicht des in die Raumform aufgefalteten Zuschnitts eines Phasen- bzw. Nulleiterstifts;
Fig.5
eine räumliche Ansicht des in die Raumform aufgefalteten Zuschnitts eines Erdleiterstifts;
Fig. 6
die räumliche Darstellung des Stanz- und Auffaltungsproszesses eines erfindungsgemäßen Erdleiterstifts;
Fig.7
einen vergrößerten Ausschnitt der räumliche Darstellung des Stanz- und Auffaltungsproszesses eines erfindungsgemäßen Erdleiterstifts aus einer anderen Perspektive gesehen als Fig. 5.
Show it:
Fig. 1
a spatial representation of an embodiment of a power supply plug with inventive connector bridge;
Fig. 2
the partially cutaway spatial representation of the embodiment as in Fig. 1 ;
Fig. 3
a spatial representation of an embodiment of a power supply connector with inventive connector bridge from a different angle than Fig. 1 ;
Fig. 4
a spatial view of the unfolded in the spatial form blank of a phase or Nulleiterstifts;
Figure 5
a spatial view of the unfolded in the spatial form blank of Erdleiterstifts;
Fig. 6
the spatial representation of the punching and Auffaltungsproszesses a Erdleiterstifts invention;
Figure 7
an enlarged section of the spatial representation of the punching and Auffaltungsproszesses a Erdleiterstifts invention seen from a different perspective than Fig. 5 ,

Fig. 1 zeigt eine räumliche Darstellung einer Ausführungsform eines Netzgerätesteckers 1 mit erfindungsgemäßer Steckerbrücke mit einem Isolierkörper 2 aus elektrisch isolierendem Material und mit Steckerstiften 3 a, b, c aus elektrisch leitendem Material. Die Kontaktfläche des Erdleiterstifts 3a umfasst die Längsseiten des Stifts in ihrer gesamten Länge. Die Kontaktflächen des Phasertleiterstifts 3b und des Nullleiterstifts 3c sind etwa auf halber Länge mit einer Isolation 4 umgeben. Sämtliche Oberflächen, welche steckdosenseitig mit stromführenden Teilen Kontakt haben könnten, sind aus Metall, insbesondere die Einführschrägen 5. Entsprechend den Forderungen der britischen Behörden, weisen die erfindungsgemäßen Steckerstifte 3 a, b, c keine Kunststoffflächen dort auf, wo die stromführenden Gegenkontakte der Steckdose mit den Steckerstiften 3 a, b, c Kontakt haben. Fig. 1 shows a three-dimensional representation of an embodiment of a power supply connector 1 with inventive connector bridge with an insulating body 2 made of electrically insulating material and with plug pins 3 a, b, c of electrically conductive material. The contact surface of the Erdleiterstifts 3a includes the longitudinal sides of the pin in its entire length. The contact surfaces of the Phasertleiterstifts 3b and the neutral conductor pin 3c are approximately halfway surrounded by an insulation 4 . All surfaces which could have contact on the plug side with live parts are made of metal, in particular the insertion bevels 5 . According to the requirements of the British authorities, the plug pins 3 a, b, c according to the invention have no plastic surfaces where the current-carrying mating contacts of the socket with the plug pins 3 a, b, c have contact.

Die Steckerstifte 3a, b, c weisen an den Nähten 6 Nasen 7a und entsprechende Aussparungen 7b auf. Dies erlaubt eine besonders feste form- und kraftschlüssige Verriegelung.The plug pins 3a, b, c have at the seams 6 lugs 7a and corresponding recesses 7b . This allows a particularly strong positive and non-positive locking.

In der erfindungsgemäßen Steckerbrücke ist eine Halterung 8 für eine Sicherung vorgesehen, welche man bei eingestecktem Gerätestecker nicht erreichen kann.In the plug bridge according to the invention, a holder 8 is provided for a backup, which can not reach when plugged device plug.

In Fig. 2 wird der Aufbau eines Netzgerätesteckers 1 mit einer erfindungsgemäßen Steckerbrücke nochmal als teilweise angeschnittene Darstellung verdeutlicht. In dieser Darstellung kann man gut die Sicherungshalterung 8 und die Niethülsen 9 erkennen, mir denen die Steckerstifte 3 a, b, c mit Stromschienen 10 ( Fig. 3 ) vernietet werden. Die Stromschienen 10 führen den Strom zu den entsprechenden Crimphülsen 11 (Fig. 3) zum Anschließen der Litzen eines Netzkabels.In Fig. 2 the structure of a power supply connector 1 with a connector bridge according to the invention again clarified as partially truncated representation. In this illustration, you can see well the fuse holder 8 and the rivet sleeves 9 , me which the plug pins 3 a, b, c with busbars 10 ( Fig. 3 ) are riveted. The conductor rails 10 lead the current to the corresponding crimp sleeves 11 ( FIG. Fig. 3 ) for connecting the wires of a power cord.

Fig. 4 zeigt eine räumliche Ansicht des in die Raumform aufgefalteten Zuschnitts eines Phasen- bzw. Nulleiterstifts 3 b, c. Hier ist gut zu erkennen, dass die Kontaktoberflächen am steckdosenseitigen Ende des Phasen- bzw. Nulleiterstifts 3 b, c vollständig aus Metall bestehen. Dabei greifen längs der Faltnaht 6 die Nasen 7a und Aussparungen 7b ineinander, um den Faltstift form- und kraftschlüssig zu verriegeln. Die britische Norm BS1363 schreibt für den Phasen- bzw. Nulleiterstift 3 b, c vor, dass steckerseitig 9,35 mm (+/- 0,15 mm) Isolierung 4 (gestrichelt angedeutet) angeordnet sein müssen. Damit die Isolierung 4 in einem Arbeitsgang mit dem Umspritzen des Isolierkörpers 2 (Fig. 1) erfolgen kann, weist das aufgefaltete Stanzteil des Phasen- bzw. Nulleiterstifts 3 b, c Langlöcher 12 auf. Durch diese Langlöcher 12 kann die Spritzgussmasse besser ins Innere des Phasen- bzw. Nulleiterstifts 3 b, c gelangen. Seitliche Ausschnitte 13 und Abprägungen 14 helfen, die Isolierung 4 sauber herzustellen und die vorgeschriebenen Konturen zu erhalten. Durch den dargestellten Aufbau, kann die Spritzgussmasse ins Innere des Phasen- bzw. Nulleiterstifts 3 b, c fließen, durch die form- und kraftschlüssig verriegelte Metalloberfläche derjenigen Oberflächen, die mit den stromführenden Teilen der Steckdose in Berührung kommen, kommt aber kein Kunststoff in Kontakt mit diesen stromführenden Teilen. Fig. 4 shows a spatial view of the unfolded in the spatial shape blank of a phase or neutral conductor 3 b, c. Here it is easy to see that the contact surfaces on the plug-side end of the phase or neutral conductor 3 b, c are made entirely of metal. In this case, engage along the fold seam 6, the lugs 7a and 7b recesses into each other to lock the folding pin positive and non-positive. The British standard BS1363 prescribes for the phase or Nulleiterstift 3 b, c that plug side 9.35 mm (+/- 0.15 mm) insulation 4 (indicated by dashed lines) must be arranged. So that the insulation 4 in one Operation with the encapsulation of the insulating body 2 ( Fig. 1 ), the unfolded stamped part of the phase conductor or neutral conductor 3 b, c has elongated holes 12 . Through these slots 12, the injection molding compound can better get into the interior of the phase or Nulleiterstifts 3 b, c. Side cutouts 13 and stampings 14 help to make the insulation 4 clean and to obtain the prescribed contours. Due to the illustrated construction, the injection-molding compound can flow into the interior of the phase or neutral conductor 3 b, c, but no plastic comes into contact with the form-fitting and force-locked metal surface of those surfaces which come into contact with the current-carrying parts of the socket with these live parts.

Der Erdleiterstift 3a, dargestellt in Fig. 5 kommt zwar nicht mit permanent stromführenden Teilen der Steckdose in Berührung, er muss jedoch gegebenenfalls statische Aufladungen oder Fehlerströme ableiten können. Aus diesem Grund verlangen die britischen Behörden auch von diesem Stift eine geschlossene Metallhülle ohne Kunststoffeinschlüsse.The Erdleiterstift 3a, shown in Fig. 5 Although it does not come into contact with permanently live parts of the socket, it may have to dissipate static charges or fault currents if necessary. For this reason, the British authorities also require from this pin a closed metal shell without plastic inclusions.

Bei dem in der DE 10 2009 049 369 A1 vorgestellten Faltstift sind nach dem Auffalten die schmalen Seiten offen. Nach dem Umspritzen weisen derartige Steckerstifte folglich an den Schmalseiten Kunststoffoberflächen auf, was nach Ansicht der britischen Behörden unzulässig ist. Auch wenn man derartige Faltstifte mit Flügeln weiterbilden würde, um die Seiten zu schließen, würden die Einführschrägen der schmalen Seiten konzeptbedingt immer noch Kunststoffoberflächen aufweisen.In the in the DE 10 2009 049 369 A1 presented folding pin are open after unfolding the narrow sides. After encapsulation, such plug pins consequently have plastic surfaces on the narrow sides, which, according to the British authorities, is inadmissible. Even if one would continue to develop such folding pens with wings to close the sides, the insertion bevels of the narrow sides would still have plastic surfaces due to the concept.

Es ist unschwer zu erkennen, dass der in Fig. 5 dargestellte Erdleiterstift 3a, inklusive der Einführschrägen 5, rundherum Metalloberflächen aufweist. Die Nasen 7a greifen in die Aussparungen 7b und verschließen den Erdleiterstift 3a entlang der Faltnaht 6 form- und kraftschlüssig. Fülllöcher 15, die später vom Isolierkörper 2 (Fig. 1) umschlossen werden, garantieren, dass die Spritzgussmasse ins Innere der Erdleiterstifts 3a gelangen kann und ihm so zusätzliche Stabilität verleiht.It is not difficult to see that in Fig. 5 illustrated Erdleiterstift 3a, including the insertion bevels 5, all around metal surfaces. The lugs 7a engage in the recesses 7b and close the Erdleiterstift 3a along the fold seam 6 positive and non-positive. Filling holes 15 , later from the insulating body 2 ( Fig. 1 ), guarantee that the Injection molding compound can get into the interior of the Erdleiterstifts 3a, giving it extra stability.

Fig. 6 zeigt die räumliche Darstellung des Stanz- und Auffaltungsproszesses eines erfindungsgemäßen Erdleiterstifts 3a. Dabei werden aus einem langen Metallblech 16, vorzugsweise aus Messingblech, zunächst die Fülllöcher 15 ausgestanzt. Das Metallblech 16 hat dabei die doppelte Breite B der Länge L des künftigen Erdleiterstifts 3a. Nach dem Ausstanzen der Fülllöcher 15 werden die Zwischenräume 17 zwischen den Erdleiterstiften 3a ausgestanzt. Die Zwischenräume 17 werden aus ökonomischen und ökologischen Gründen so klein wie möglich gehalten, um den produzierten Metallabfall zu reduzieren. Die Außenkonturen des Erdleiterstifts 3a mit den Nasen 7a und Aussparungen 7b, die beim Auffalten ineinandergreifen sind jetzt bereits gut zu erkennen. Mit einem konisch zulaufenden Stanzwerkzeug wird jetzt aus dem verbliebenen Steg 18 die Niethülse 9 teils ausgestanzt, teil eingedrückt. Fig. 6 shows the spatial representation of the punching and Auffaltungsproszesses a Erdleiterstifts 3a according to the invention. In this case, the filling holes 15 are first punched out of a long metal sheet 16, preferably made of sheet brass. The metal sheet 16 has twice the width B of the length L of the future Erdleiterstifts 3a. After punching out the filling holes 15, the gaps 17 between the Erdleiterstiften 3 a are punched out. The gaps 17 are kept as small as possible for economic and environmental reasons, in order to reduce the produced metal waste. The outer contours of Erdleitererstifts 3a with the lugs 7a and recesses 7b, which mesh with each other when unfolding are now already clearly visible. With a tapered punching tool, the rivet sleeve 9 is now partially punched out of the remaining web 18 , partially pressed.

Danach folgt das Aufbiegen der schmalen Seiten. Der Steg 18 wird nochmals auf die Breite der zukünftigen Dicke D des Erdleiterstifts 3a verschmälert.This is followed by the bending of the narrow sides. The web 18 is again narrowed to the width of the future thickness D of the Erdleiterstifts 3a.

Das Auffalten des Erdleiterstifts 3a erfolgt entlang der Kanten 19 des Stegs 18. Die Nasen 7a greifen dabei in die Aussparungen 7b und verriegeln den Erdleiterstift form- und kraftschlüssig.The unfolding of the Erdleiterstifts 3a along the edges 19 of the web 18. The lugs 7a engage in the recesses 7b and lock the Erdleiterstift positive and non-positive.

In Fig. 7 ist der Prozess aus einem anderen Blickwinkel dargestellt. Aus dieser Perspektive sieht man besonders gut die teils ausgestanzte, teil eingedrückte Niethülse 9.In Fig. 7 the process is presented from a different angle. From this perspective you can see especially well the partly punched out, partially depressed rivet sleeve 9.

Der Phasen- bzw. Nulleiterstift 3b, 3c werden analog aufgefaltet, wobei statt der Füllöcher 15 die Langlöcher 12 eingestanzt werden und zusätzlich noch die Ausschnitte 13 und Abprägungen 14 ausgestanzt bzw. abgeprägt werden.The phase or Nulleiterstift 3b, 3c are unfolded analogously, instead of the filling holes 15, the slots 12 are punched and additionally the cutouts 13 and stampings 14 are punched or stamped.

BezugszeichenlisteLIST OF REFERENCE NUMBERS

11
NetzgerätesteckerPower plug
22
Isolierkörperinsulator
3a3a
ErdleiterstiftErdleiterstift
3b3b
PhasenleiterstiftPhase conductor pin
3c3c
NullleiterstiftNeutral pen
44
Isolierung gemäß BS 1363Insulation according to BS 1363
55
Einführschrägechamfer
66
Faltnahtfolding seam
7a7a
Nasenose
7b7b
Aussparungrecess
88th
Sicherungshalterfuse holder
99
Niethülserivet sleeve
1010
Stromschieneconductor rail
1111
Crimphülse für KabellitzeCrimp barrel for cable strand
1212
LanglochLong hole
1313
Ausschnittneckline
1414
AbprägungAbprägung
1515
Fülllochfill hole
1616
Langes MetallblechLong sheet metal
1717
Zwischenräumeinterspaces
1818
Stegweb
1919
Faltkantenfolding
LL
Länge des jeweiligen Steckerstifts 3a, b, cLength of the respective connector pin 3a, b, c
BB
Breite des Metallblechs 16Width of the metal sheet 16
DD
Dicke des jeweiligen Steckerstifts 3a, b, cThickness of the respective plug pin 3a, b, c

Claims (10)

  1. Connector bridge for an electrical device connector (1) for connecting electrical devices, in particular household appliances, to a plug socket of an alternating current network, the device connector (1) being formed as a unit by the connector bridge which is connected to the end piece of a three-core connection cable for the device and which is extrusion-coated in an injection mould, and which is itself constructed from a dimensionally stable insulation member (2) for receiving and fixing a rectangular phase conductor pin (3b), rectangular neutral conductor pin (3c) and rectangular earth conductor pin (3a), the phase, neutral and earth conductor pins (3a, b, c) also being injection moulded in/on in the same operating step as the injection moulding of the insulation member (2) in openings of the insulation member (2) corresponding to the cross-section thereof, the phase, neutral and earth conductor pins (3a, b, c) projecting relative to the connector bridge and the device connector (1) to a sufficient extent to be introduced into the plug socket, the phase conductor pin (3b), neutral conductor pin (3c) and earth conductor pin (3a) each having inclined introduction members (5), the phase conductor pin (3b) and neutral conductor pin (3c) each having insulation (4) at the insulation member side and the phase conductor pin (3b), neutral conductor pin (3c) and earth conductor pin (3a) each being in the form of a folding pin which is drawn into its definitive spatial shape from an initially flat punched component comprising metal sheet (16), is folded and is filled with plastics material in its empty and intermediate spaces during the injection moulding process of the insulation member (2) in such a manner that, after the injection moulding process, the phase, neutral and earth conductor pins (3a, b, c) have the definitive contour thereof, characterised in that,
    after the connector bridge has been extrusion-coated, at the plug socket side all the surfaces of the phase, neutral and earth conductor pins (3a, b, c) produced in that manner, including the inclined introduction members (5), at least as far as the insulation (4) at the insulation member side comprise the metal sheet (16),
    in that the phase, neutral and earth conductor pins (3b, c, a) have projections (7a) and cut-outs (7b) at the folding seams (6), with the projections (7a) coming to rest in a deformed state in the cut-outs (7b) during the folding operation and consequently allowing a positive-locking and non-positive-locking connection,
    in that a large number of sheet metal strips (17) are punched out of the long metal sheet (16), with a web (18) remaining at the centre of the transverse axis and forming the connector-side end of the phase, neutral and earth conductor pins (3a, b, c) after the folding operation.
  2. Connector bridge according to claim 1, characterised in that the flat punched component, from which the phase, neutral and earth conductor pins (3a, b, c) are drawn and folded into the definitive spatial shape thereof, is a long metal sheet (16) having the width (B) of double the length (L) of the phase, neutral and earth conductor pins (3a, b, c) before the punching and folding operation.
  3. Connector bridge according to claim 2, characterised in that a conical hole which forms a rivet sleeve (9) after the folding operation is punched into the web (18) with a punching machine which tapers forwards.
  4. Connector bridge according to either claim 2 or claim 3, characterised in that the phase, neutral and earth conductor pins (3b, c, a) are folded from the sheet metal pieces remaining between the punched-out sheet metal strips (17).
  5. Connector bridge according to any one of the preceding claims, characterised in that elongate holes (12) which are positioned after the folding operation at the wide sides of the rectangular phase conductor pin (3b) or the neutral conductor pin (3c) are punched out of the flat punched component for the phase conductor pin (3b) or the neutral conductor pin (3c) in a mirror-symmetrical manner relative to the longitudinal axis of the phase conductor pin (3b) or the neutral conductor pin (3c).
  6. Connector bridge according to any one of the preceding claims, characterised in that the phase conductor pin (3b) and the neutral conductor pin (3c) have lateral cut-outs (13).
  7. Connector bridge according to any one of the preceding claims, characterised in that the phase conductor pin (3b) and the neutral conductor pin (3c) have an impression (14), preferably of from 0.5 mm to 0.3 mm, at least at one lateral flank.
  8. Connector bridge according to any one of the preceding claims, characterised in that the phase, neutral and earth conductor pins (3b, c, a) each have a hollow rivet (9) at an end thereof at the insulation member side.
  9. Connector bridge according to any one of the preceding claims, characterised in that the flat punched components for the phase, neutral and earth conductor pins (3b, c, a) comprise electrically conductive material, preferably brass sheet.
  10. Connector bridge according to any one of the preceding claims, characterised in that an electrical fuse is provided to prevent excessively high current flow.
EP12723471.4A 2011-05-25 2012-05-23 Plug bridge with closed folding pins Not-in-force EP2715874B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE202011101335U DE202011101335U1 (en) 2011-05-25 2011-05-25 Connector bridge with closed folding pins
PCT/EP2012/059615 WO2012160099A1 (en) 2011-05-25 2012-05-23 Plug bridge with closed folding pins

Publications (2)

Publication Number Publication Date
EP2715874A1 EP2715874A1 (en) 2014-04-09
EP2715874B1 true EP2715874B1 (en) 2015-07-08

Family

ID=45471441

Family Applications (1)

Application Number Title Priority Date Filing Date
EP12723471.4A Not-in-force EP2715874B1 (en) 2011-05-25 2012-05-23 Plug bridge with closed folding pins

Country Status (4)

Country Link
EP (1) EP2715874B1 (en)
CN (1) CN103733438A (en)
DE (2) DE202011101335U1 (en)
WO (1) WO2012160099A1 (en)

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN109127990A (en) * 2018-08-03 2019-01-04 广东顺德安电电器实业有限公司 A kind of English rule plug of novel riveting method
CN117117568B (en) * 2023-10-23 2024-02-02 深圳市西点精工技术有限公司 Connector

Family Cites Families (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2040600B (en) * 1978-12-15 1983-07-27 Hotpoint Ltd Electric plug
GB2054283B (en) * 1979-06-13 1983-04-27 Taylor J C Electrical connector with contact members formed from sheet metal
GB2092836B (en) 1981-02-05 1984-09-19 Lucas Industries Ltd Electrical plugs
DE4314195A1 (en) 1993-04-30 1994-11-03 M & K Metall Und Kunststoff Gm Plug pin and plug link
DE19801896C1 (en) 1998-01-20 1999-06-17 Taller Gmbh Plug bridge for electric appliance plug
DE10051348C2 (en) 2000-07-25 2002-06-13 Taller Gmbh Plug bridge with insertion aid arrangement
DE102004063485A1 (en) * 2004-12-23 2006-07-13 Taller Gmbh plug link
DE102007009422A1 (en) 2007-02-23 2008-09-25 Taller Gmbh pin
DE102009049369B4 (en) 2009-10-14 2011-06-22 Taller GmbH, 76337 Plug bridge with folding pins

Also Published As

Publication number Publication date
CN103733438A (en) 2014-04-16
WO2012160099A1 (en) 2012-11-29
DE202011101335U1 (en) 2011-12-12
EP2715874A1 (en) 2014-04-09
DE102012207445A1 (en) 2012-11-29

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