EP2860829B1 - Electrical contact element, connector and manufacturing method - Google Patents

Electrical contact element, connector and manufacturing method Download PDF

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Publication number
EP2860829B1
EP2860829B1 EP14003492.7A EP14003492A EP2860829B1 EP 2860829 B1 EP2860829 B1 EP 2860829B1 EP 14003492 A EP14003492 A EP 14003492A EP 2860829 B1 EP2860829 B1 EP 2860829B1
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EP
European Patent Office
Prior art keywords
contact element
contact
plug
connector
forming
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Application number
EP14003492.7A
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German (de)
French (fr)
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EP2860829A1 (en
Inventor
Michael Quiter
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Yamaichi Electronics Deutschland GmbH
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Yamaichi Electronics Deutschland GmbH
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Publication date
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Publication of EP2860829A1 publication Critical patent/EP2860829A1/en
Application granted granted Critical
Publication of EP2860829B1 publication Critical patent/EP2860829B1/en
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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
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/16—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for manufacturing contact members, e.g. by punching and by bending
    • 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
    • H01R13/02—Contact members
    • H01R13/04—Pins or blades for co-operation with sockets
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-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
    • H01R4/24—Connections using contact members penetrating or cutting insulation or cable strands
    • H01R4/2416—Connections using contact members penetrating or cutting insulation or cable strands the contact members having insulation-cutting edges, e.g. of tuning fork type
    • H01R4/242—Connections using contact members penetrating or cutting insulation or cable strands the contact members having insulation-cutting edges, e.g. of tuning fork type the contact members being plates having a single slot
    • H01R4/2425—Flat plates, e.g. multi-layered flat plates
    • H01R4/2429—Flat plates, e.g. multi-layered flat plates mounted in an insulating base
    • H01R4/2433—Flat plates, e.g. multi-layered flat plates mounted in an insulating base one part of the base being movable to push the cable into the slot

Definitions

  • the invention relates to an electrical contact element for a plug connector, a plug connector and a method for producing an electrical contact element.
  • Electrical contact elements are used in electrical connectors to establish electrical contact between an electrical wire or cable and a mating connector.
  • the contact elements are designed to be rigid, at least in some areas, in order to withstand mechanical stress during the plugging of the connector into the complementary connector.
  • the quality of the electrical connection between the contact element and corresponding complementary contact elements of the complementary connector is of decisive importance, particularly when transmitting high-frequency electrical signals via such connectors.
  • the electrical contact resistance between the two should be as low as possible and as constant as possible as a function of the frequency.
  • the surface of the contact element which is designed to come into contact with the complementary contact element is usually machined, for example turned to a cylindrical shape.
  • the mechanical processing of the contact element leads to a complex production process.
  • the pamphlet EP 1 231 675 A2 discloses an electrical contact element and a method for its manufacture, in which a preform is stamped out and its contact area is folded along its longitudinal axis.
  • the goal here is to obtain an approximately square cross-section with side surfaces that are as planar as possible.
  • the pamphlet WO 2007/009487 A1 relates to another electrical contact element whose contact area is folded along its longitudinal axis into a square cross-section.
  • the contact area of the contact element is then rotated by 90 degrees in relation to the rest of the contact element, so that the electrical contact on one side of the contact area without Nut comes about.
  • the pamphlet U.S. 4,434,552 discusses a method of manufacturing a cylindrical contact element in which an outer shell of the contact element is stamped and rolled by cold forming and an inner part placed in the outer shell from sheet metal.
  • the pamphlet EP 1 403 975 A2 describes a contact element with a hollow mounting portion having lateral and horizontal windows for inserting a cable.
  • the pamphlet U.S. 4,969,839 shows a socket having insulation displacement contacts for attaching cables to the female contact elements of the socket.
  • the pamphlet DE 202 08 436 U1 discloses a one-piece contact element made of stamped and rolled sheet metal material with a mating end and a connecting end, the mating end being designed as a pin and having a square cross-section. Furthermore, the edges of the pen are rounded.
  • the contact element can be produced easily and quickly, with the plug-in contact area having increased mechanical strength due to the essentially prismatic shape.
  • the electrical contact element is made of an electrically conductive material, in particular a metal, in which case an electrical current can flow from the plug contact area to the line contact area.
  • the line contact area of the contact element is connected to an associated electrical line electrically contactable or electrically connectable.
  • the electrical line can be attached to the line contact area in a detachable or non-detachable manner.
  • the plug-in contact area with a associated complementary contact element of the complementary connector electrically or mechanically contactable. An electric current can therefore flow from the electric line via the contact element to the complementary contact element.
  • forming describes manufacturing processes in which the material of the contact element, in particular a metal, is plastically brought into a different shape.
  • an originally shaped, for example a cast, rolled or punched starting material, ie the preform is formed into the final contact element.
  • the material retains its mass and cohesion during forming.
  • forming within the meaning of the invention differs from a general deformation of the material in that the change in shape is brought about in a targeted manner, while deformation represents an untargeted elastic or plastic change in shape, for example when Bending during insertion of the contact element.
  • neither material is added nor removed from the contact element during the forming process.
  • forming in particular does not include machining, such as turning, milling, grinding, drilling, etc., or machining to add material, such as casting, soldering, welding, coating, anodic or cathodic deposition of material on the surface.
  • the plug contact area can in particular have been formed by pressure forming. In other words, the forming of the preform takes place with prevailing compressive stress.
  • the plug contact area can preferably be formed by pressing between two dies or by embossing between embossing dies. Further alternatively, the plug-in contact area could be formed by rolling.
  • the contact element is formed in one piece from electrically conductive material.
  • the contact element can be formed from a metal stamped part (the preform), which has been shaped in the plug-in area. Due to the one-piece design, the electrical conductivity within the contact element is advantageously particularly low-resistance, since there are no joints at which a contact resistance occurs. High-frequency electrical signals are also conducted through the contact element with little distortion.
  • the contact element can in particular consist of a copper alloy, for example a copper-tin alloy or a copper-nickel alloy. To reduce the electrical contact resistance in the line contact area and/or in the plug contact area, the line contact area and/or the plug contact area can be coated or plated or galvanized with gold, silver or an alloy thereof.
  • the plug-in contact area of the contact element is preferably designed to be free of cavities.
  • the formed plug-in contact area can be solid. This advantageously results in increased mechanical strength in the plug-in contact area compared to other areas of the contact element.
  • the plug contact area is not designed as a hollow prism but as a solid prism.
  • the plug-in contact area of the contact element can preferably be inserted linearly, at least in areas, along an insertion direction E into the complementary connector.
  • the electrical contact between the contact element and a complementary contact element of the complementary connector can be made by plugging the plug-in contact area of the contact element along the insertion direction E into the complementary contact element.
  • the insertion direction E is in particular oriented parallel to the cylinder axis of the essentially cylindrical plug contact area.
  • the plug-in contact area has sufficient rigidity along the insertion direction E, as a result of which insertion into the associated complementary contact element is made possible.
  • the plug contact area can have a diameter of about 0.5 mm to about 4 mm, preferably about 0.6 mm or about 1 to about 2 mm.
  • the length of the plug contact area can be approximately 3 mm to approximately 10 mm, preferably approximately 4 mm to approximately 6 mm.
  • the line contact area is designed as an insulation displacement contact.
  • an electrical line can advantageously be electrically contacted with the contact element in a simple and reliable manner.
  • the electrical line can be connected without tools to the line contact area designed as an insulation displacement contact.
  • the contact element preferably also has at least one fastening area, with which the contact element can be fastened to an associated, complementary fastening area of the plug connector.
  • the fastening area can be designed to be resilient or springy. As a result, after insertion into a contact element receptacle of the connector, the contact element can latch or lock there or with the contact element receptacle engage in such a way that the contact element is fixed in the contact element receptacle.
  • the fastening area can be formed in one piece with the contact element, for example by stamping a latching element or a projection.
  • resiliently deformable as it is understood in the context of this invention describes that the at least one fastening area essentially returns to its original shape and/or position after mechanical stress or elastic or plastic deformation by a force in a stress direction returns.
  • the mechanical loading or deformation of the at least one fastening area takes place, for example, during the insertion of the contact element into an associated contact element receptacle, as a result of which a force in the loading direction is applied to the at least one fastening area by means of the wall of the contact element receptacle.
  • the connector can have a contact element holder for receiving at least one contact element.
  • the contact element holder can have an associated contact element receptacle for each contact element, in which the contact element is accommodated and fixed at least in regions.
  • the connector can have two, three, four, five, six, seven, eight, nine, ten or more contact elements.
  • the connector can have a housing in which the contact element holder is arranged.
  • the housing can be made of metal or plastic, for example.
  • the housing can be made of die-cast zinc, die-cast aluminum or impact-resistant polyamide or ABS.
  • a single contact element or a multiplicity of contact elements can be held by the contact element holder, so that each of the contact elements can be inserted into an associated contact element of a complementary plug connector.
  • the contact elements can be aligned parallel to one another.
  • the longitudinal extensions of the plug-in contact areas of all contact elements are aligned parallel to one another.
  • the area of the preform to be formed is formed into an essentially prismatic plug contact area in such a way that the plug contact area has an n-cornered cross section with n ⁇ 6 or n ⁇ 8 or n ⁇ 12.
  • the contact element can be formed in a simple manner using two processing steps.
  • a metal sheet is generally provided as the blank, from which a preform is punched.
  • the provision of the preform can in particular include stamping the preform from a metal sheet. This stamping step enables easy mass production of the preforms.
  • different metal sheets can be provided as raw material in a simple manner. After punching, this is done in sections Reshaping the preform to form the plug contact area of the contact element.
  • the forming is preferably carried out by cold forming or hot forming.
  • the cold forming can be carried out in an efficient manner without heating the preform.
  • Cold forming refers to a forming in which the preform is formed in the cold state, for example at room temperature, so that the material in the plug-in contact area is solidified.
  • the method preferably includes the step of forming at least one fastening area, with which the contact element can be fastened to a complementary fastening area of the plug connector.
  • the fastening area can be formed in one piece with the contact element, for example by stamping a latching element or a projection.
  • the figure 1 shows a perspective view of an embodiment of a contact element 1 with a line contact area 3, a plug-in contact area 5 and a fastening area 7.
  • the line contact area 3 is designed as an insulation displacement contact in order to connect an electrical line of a cable 29 (in figure 4 shown) electrically closed to contact.
  • the line contact area 3 designed as an insulation displacement contact advantageously allows simple and reliable electrical contacting of the electrical line.
  • the electrical line can be electrically contacted with the contact element 1 in particular without tools, as a result of which the contact element 1 can advantageously be used in connectors that can be assembled in the field.
  • the plug-in contact area 5 is essentially prism-shaped, with the base of the in the figure 1 the prism shown represents an octagon. It goes without saying that prisms can also be provided which have a hexagon, a decagon, a dodecagon or a polygon with a number of corners greater than twelve.
  • the longitudinal axis A of the prism, which forms the plug-in contact area 5, is oriented parallel to an insertion direction E, along which the contact element 1 can be inserted at least in some areas into a complementary connector (not shown) in order to electrically connect the contact element 1 to a complementary contact element of the complementary connector associate.
  • substantially prismatic describes that the plug contact area 5 can have slight deviations from the prism shape, such as a rounded end face 5a, which can taper conically or pointedly in the direction of insertion E in order to facilitate insertion of the contact element 1 into the to facilitate complementary contact element.
  • the plug contact area 5 can deviate from a target thickness or a target width of up to about 10% along a thickness direction D, which is essentially perpendicular to the insertion direction E, or along a width direction B, which is also essentially perpendicular to the insertion direction E. preferably about 5% exhibit.
  • the contact element 1 can preferably have a greater width extension in the width direction B in some areas than the thickness extension in the thickness direction D, in particular in the area of the line contact area 3.
  • the fastening area 7 of the contact element 1 can have a resiliently deformable latching element 7a, with which the contact element 1 can be locked in a contact element receptacle of a connector (in the figure 2 shown) can be attached. Due to the resilient deformability of the latching element 7a, a mechanical load on the latching element 7a along a loading direction B′ leads to a deformation or displacement of the latching element 7a. As soon as the mechanical stress along the stress direction B' ceases, the latching element 7a essentially returns to its original shape and/or position.
  • resilient deformability includes elastic deformability.
  • the fastening area 7 can have an engagement element 7b, which is designed to engage with a complementary engagement element of the contact element receptacle (in figure 2 shown) to engage to inhibit displacement of the contact element 1 within the contact element receptacle.
  • the embodiment shown has the engagement element 7b along the direction of insertion E tapering section on which opposite to the direction of insertion E is an undercut. Material of the contact element receptacle, for example, can penetrate into the undercut by plastic and/or elastic displacement in order to frictionally or positively engage with the engagement element 7b.
  • the one in the figure 1 shown embodiment of the contact element 1 is integrally formed.
  • a metal sheet is provided, from which a preform is stamped.
  • the punching tool is moved along the thickness direction D to remove the preform from the punching out sheet metal. Consequently, the punched edge 9 produced during punching is oriented parallel to the thickness direction.
  • the insulation displacement contact 3 and the engagement element 7d can be formed during the stamping.
  • the preform can be bent in certain areas, for example in order to form the latching element 7a of the fastening area 7 .
  • the preform can have further bending areas 9a, in which case the bending can be carried out simultaneously with or after the stamping.
  • the plug contact area 5 is shaped or formed by area-wise reshaping of the preform.
  • the forming takes place in a production step in which the material of the preform is plastically brought into a different shape in some areas.
  • the stamped edge 9 is generally formed in the formed plug contact area 5 in such a way that the stamped edge 9 can no longer be recognized as such.
  • the cross section of the preform is essentially rectangular in a surface that is perpendicular to the insertion direction E
  • the cross section of the formed plug contact area 5 of the contact element 1 is essentially a polygon or n-corner with n greater than five.
  • the plug contact area 5 can have a hexagonal, an octagonal or a dodecagonal cross section.
  • the contact element 1 is formed by forming the preform.
  • the plastic forming is material-preserving, so that the preform and the contact element 1 have an identical mass.
  • the forming can be carried out in a simple manner by means of embossing tools or dies (upper die and lower die), a negative form of the plug contact area 5 to be formed being formed between the embossing tools or dies.
  • embossing tools or dies upper die and lower die
  • a negative form of the plug contact area 5 to be formed being formed between the embossing tools or dies.
  • To shape the preform it is inserted at least in certain areas into the forming tools, i.e. the embossing tools or dies, and then pressure is applied by means of the forming tools, as a result of which the material of the preform is shaped in order to fill the negative mold formed in the forming tools and thereby assume the desired shape .
  • the forming in particular from a machining, such as turning, in which material is removed from the preform to achieve the desired cylindrical shape. Since, in contrast to machining, the material of the preform remains in the area of the plug contact area 5, the preform can have less material in this area in order to achieve a desired final thickness of the plug contact area 5 of the contact element 1. It goes without saying that the plastic forming of the preform can be carried out both as cold forming and as hot forming.
  • the cold forming of the preform allows faster processing since it is not necessary to heat the preform. At the same time, cold forming increases the strength in the formed area, ie in plug contact area 5 of the contact element.
  • the contact element 1 has greater strength in the area of the plug-in contact area 5, so that the plug-in contact area 5 can withstand greater mechanical loads during plugging.
  • toughness is reduced by cold forming. If a reduction in toughness is not desired, forming can alternatively be carried out as hot forming.
  • the contact element 1 can be formed in particular from a metal sheet which consists of a copper alloy, for example a copper-tin alloy or a copper-nickel alloy.
  • the alloy of the contact element 1 is selected on the basis of the necessary mechanical and electrical properties of the contact element 1.
  • the contact element 1 can be plated or galvanized at least in areas with gold, silver or a gold-silver alloy. This advantageously also prevents corrosion of the contact element 1 on the plated or galvanized areas.
  • the figure 2 shows a perspective sectional view of a contact element holder 11, which has a plurality of contact element receptacles 13, in each of which an associated contact element 1 is arranged and fastened.
  • the Contact element holder 11 is formed from an electrically insulating material, preferably a plastic such as polyamide, ABS, polybutylene terephthalate (PBT) or polycarbonate.
  • PBT polybutylene terephthalate
  • eight contact elements 1 are held by the contact element holder 11, two options are available.
  • the contact element holder 11 can be provided, for example in the form of an injection molded part made of a thermoplastic material.
  • a number of contact element receptacles 13 corresponding to the contact elements 1 to be received are formed in the body of the contact element holder 11 .
  • An associated contact element 1 can be inserted into each of the contact element receptacles 13 along the second insertion direction E′ in order to arrange the contact element 1 in the contact element holder 11 .
  • the engagement element 7b of the contact element 1 can engage or frictionally engage with the wall of the contact element receptacle. This prevents the contact element 1 from being displaced relative to the contact element holder 11 counter to the second insertion direction E′.
  • the wall of the contact element receptacle 13 can come into mechanical contact with the resiliently deformable latching element 7a, with the latching element 7a being deformed along the loading direction B′.
  • the wall of the contact element receptacle 13 can have a recess in the wall 13a as a preferred complementary latching element 13a, so that the latching element 7a can engage in the complementary latching element 13a when the contact element 1 is inserted into the contact element receptacle 13 along the second insertion direction E' in such a way that that a predetermined arranging position is reached.
  • the latching element 7a In the arrangement position, the latching element 7a is displaced against the loading direction B' due to the resilient deformability of the latching element 7a, so that the latching element 7a engages or locks with the complementary latching element 13a.
  • the contact element 1 is fixed in the arrangement position within the contact element receptacle 13 .
  • the contact element holder 11 can be formed around a plurality of contact elements 1 provided.
  • the contact element holder 11 can be formed as an injection molded part from a thermoplastic elastomer or thermoplastic polymer if a plurality of contact elements 1 are held in position by means of a holding device (not shown), so that there is an intimate connection between the contact element holder 11 and the contact elements 1 results.
  • the contact elements 1 are permanently connected to the contact element holder 11 .
  • the contact element receptacles 13 then correspond to the gaps in the material of the contact element holder 11, which are caused by the presence of the contact elements 1.
  • the contact elements 1 can be arranged along a circular line in the contact element holder 11 .
  • the contact elements 1 and in particular the latching elements 7a can be arranged in such a way that the loading direction B' for all contact elements 1 is oriented radially outwards or inwards.
  • the contact element holder 11 can be designed to be axially symmetrical about an axis of symmetry, with the axis of symmetry preferably being oriented parallel to the insertion direction E.
  • the figure 3 shows a perspective view of a first part 15 of a connector with a in the figure 2 shown contact element holder 11.
  • the contact element holder 11 is arranged in a housing 17, which is preferably made of metal or impact-resistant plastic.
  • the housing 17 of the first part of the connector 15 has a connection configuration 17a, which enables a second part 19 of the connector to be inserted at least in regions along a third insertion direction E" into the housing 17 of the first part 15 of the connector.
  • the figure 4 Figure 1 shows a perspective view of the second part 19 of the connector with a housing 21 having a complementary terminal configuration 21a engageable with the terminal configuration 17a.
  • the connection configuration 17a and the complementary connection configuration 21a can be screwed together.
  • the housing 21 can also be made of metal or impact-resistant plastic.
  • the second part 19 of the connector also has a line holder 23 in which a multiplicity of line receptacles 25 are formed.
  • the line receptacles 25 are designed to each accommodate an associated electrical line 27 at least in certain areas.
  • the electrical lines 27 are part of a cable 29, which is guided along a fourth insertion direction E′′′ through a passage opening in the housing 21 of the second part 19 of the connector, the sheathing of the cable 29 being removed at least in the area of the line holder 23 in order to allow the electrical Lines 27 along a spreading direction S, which is oriented substantially perpendicular to the fourth insertion direction E′′′, to spread or bend radially outwards, so that the electrical lines can each be accommodated in an associated line receptacle 25 .
  • the cable 29 can be attached to the housing 21 by means of the strain relief 31 .
  • the strain relief 31 can be designed as a PG screw connection.
  • connection configuration 17a engages with the complementary connection configuration 21a, so that both connector parts 15, 19 can be connected to one another .
  • the insulation displacement contacts 3 of the first part 15 of the connector are received in the associated insulation displacement contact receptacles 25a of the line receptacle 25 counter to the third insertion direction E ⁇ , as a result of which the electrical lines 27, which are in the line receptacles 25, are cut through the associated insulation displacement contacts 3 and electrically contacted .
  • the electrical and mechanical connection of the two parts 15, 19 of the connector takes place by plugging the second part 19 and the first part 15 of the connector together along the third insertion direction E". After the two parts 15, 19 of the connector have been joined together, the cable 29 and the connector are electrically and mechanically connected to each other, thus assembling the cable 29.
  • the connector can be designed in particular as a plug connector, which can be plugged into a complementary connector (not shown) along an insertion direction E in order to connect the cable 29 to a further electrical
  • the connector can be an M12 connector, which is designed to establish an Ethernet connection according to category 6 A (CAT 6 A ).
  • the connector shown in the figures can advantageously be assembled in the field a cable 29 in the field, ie at the site without Spezia oil tool, to be assembled. Consequently, only a knife or stripping pliers is required to remove the insulating jacket of the cable 29 in certain areas and to cut off the protruding parts of the electrical lines 27 arranged in the line receptacles 25 . The subsequent electrical contacting and attachment of the connector to the electrical lines 27 of the cable 29 then takes place without tools.
  • the second insertion direction E′ is preferably oriented parallel to the insertion direction E.
  • the third insertion direction E" is more preferably oriented parallel to the second insertion direction E', particularly preferably also to the insertion direction E.
  • the fourth insertion direction E'" is oriented parallel to the third insertion direction E", particularly preferably also to the second insertion direction E'
  • the four insertion directions E, E′, E′′ and E′′′ can be oriented parallel to one another or be identical.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Manufacturing Of Electrical Connectors (AREA)
  • Connector Housings Or Holding Contact Members (AREA)

Description

Die Erfindung betrifft ein elektrisches Kontaktelement für einen Steckverbinder, einen Steckverbinder sowie ein Verfahren zum Herstellen eines elektrischen Kontaktelements.The invention relates to an electrical contact element for a plug connector, a plug connector and a method for producing an electrical contact element.

Elektrische Kontaktelemente finden in elektrischen Verbindern Verwendung, um den elektrischen Kontakt zwischen einer elektrischen Leitung bzw. einem Kabel und einem komplementären Verbinder herzustellen. Dazu sind die Kontaktelemente zumindest bereichsweise starr ausgebildet, um einer mechanischen Beanspruchung während des Steckens des Verbinders in den komplementären Verbinder standzuhalten.Electrical contact elements are used in electrical connectors to establish electrical contact between an electrical wire or cable and a mating connector. For this purpose, the contact elements are designed to be rigid, at least in some areas, in order to withstand mechanical stress during the plugging of the connector into the complementary connector.

Insbesondere bei der Übertragung von hochfrequenten elektrischen Signalen über solche Verbinder ist die Qualität der elektrischen Verbindung zwischen dem Kontaktelement zu entsprechenden komplementären Kontaktelementen des komplementären Verbinders von entscheidender Bedeutung. Insbesondere sollte der elektrische Übergangswiderstand zwischen beiden möglichst gering und als Funktion der Frequenz möglichst konstant sein.The quality of the electrical connection between the contact element and corresponding complementary contact elements of the complementary connector is of decisive importance, particularly when transmitting high-frequency electrical signals via such connectors. In particular, the electrical contact resistance between the two should be as low as possible and as constant as possible as a function of the frequency.

Dazu wird die Oberfläche des Kontaktelements, welche ausgelegt ist, in Kontakt mit dem komplementären Kontaktelement zu treten, in der Regel bearbeitet, beispielsweise auf eine zylindrische Form überdreht. Insbesondere die mechanische Bearbeitung des Kontaktelements führt zu einem aufwendigen Produktionsprozeß.For this purpose, the surface of the contact element which is designed to come into contact with the complementary contact element is usually machined, for example turned to a cylindrical shape. In particular, the mechanical processing of the contact element leads to a complex production process.

Die Druckschrift EP 1 231 675 A2 offenbart ein elektrisches Kontaktelement und ein Verfahren zu seiner Herstellung, bei dem ein Vorformling ausgestanzt und dessen Kontaktbereich entlang seiner Längsachse gefaltet wird. Ziel ist es hierbei, einen näherungsweise quadratischen Querschnitt mit möglichst planen Seitenflächen zu erhalten.The pamphlet EP 1 231 675 A2 discloses an electrical contact element and a method for its manufacture, in which a preform is stamped out and its contact area is folded along its longitudinal axis. The goal here is to obtain an approximately square cross-section with side surfaces that are as planar as possible.

Die Druckschrift WO 2007/009487 A1 betrifft ein weiteres elektrisches Kontaktelement, dessen Kontaktbereich entlang seiner Längsachse zu einem quadratischen Querschnitt gefaltet wird. Um durch auf einer Seite des Kontaktbereichs die entlang dessen Längsachse verbleibende Nut verschlechterte elektrische Kontakteigenschaften zu vermeiden, wird abschließend der Kontaktbereich des Kontaktelements um 90 Grad gegenüber dem restlichen Kontaktelement verdreht, so dass der elektrische Kontakt bei bestimmungsgemäßer Verwendung des Kontaktelements auf einer Seite des Kontaktbereichs ohne Nut zustande kommt.The pamphlet WO 2007/009487 A1 relates to another electrical contact element whose contact area is folded along its longitudinal axis into a square cross-section. In order to avoid deteriorated electrical contact properties due to the groove remaining along its longitudinal axis on one side of the contact area, the contact area of the contact element is then rotated by 90 degrees in relation to the rest of the contact element, so that the electrical contact on one side of the contact area without Nut comes about.

Die Druckschrift US 4,434,552 diskutiert ein Verfahren zur Herstellung eines zylindrischen Kontaktelementes, bei dem eine äußere Hülle des Kontaktelementes durch Kaltumformung und ein in der äußeren Hülle platziertes Innenteil aus einem Blech gestanzt und gerollt wird.The pamphlet U.S. 4,434,552 discusses a method of manufacturing a cylindrical contact element in which an outer shell of the contact element is stamped and rolled by cold forming and an inner part placed in the outer shell from sheet metal.

Die Druckschrift EP 1 403 975 A2 beschreibt ein Kontaktelement mit einem hohlen Befestigungsabschnitt, der seitliche und horizontale Fenster zum Einführen eines Kabels besitzt.The pamphlet EP 1 403 975 A2 describes a contact element with a hollow mounting portion having lateral and horizontal windows for inserting a cable.

Die Druckschrift US 4,969,839 zeigt eine Buchse, die über Schneidklemmkontakte zur Befestigung von Kabeln an den weiblichen Kontaktelementen der Buchse verfügt.The pamphlet U.S. 4,969,839 shows a socket having insulation displacement contacts for attaching cables to the female contact elements of the socket.

Die Druckschrift DE 202 08 436 U1 offenbart ein einstückiges Kontaktelement aus gestanztem und gerolltem Blechmaterial mit einem Steckende und einem Anschlussende, wobei das Steckende als Stift ausgebildet ist und einen quadratischen Querschnitt aufweist. Ferner sind die Kanten des Stiftes gerundet.The pamphlet DE 202 08 436 U1 discloses a one-piece contact element made of stamped and rolled sheet metal material with a mating end and a connecting end, the mating end being designed as a pin and having a square cross-section. Furthermore, the edges of the pen are rounded.

Es ist eine Aufgabe der vorliegenden Erfindung, ein elektrisches Kontaktelement, einen Verbinder und ein Verfahren zur Herstellung des Kontaktelements bereitzustellen, wobei dieIt is an object of the present invention to provide an electrical contact element, a connector and a method for manufacturing the contact element, wherein the

Herstellung des Kontaktelements bzw. des Verbinders einfacher und schneller durchführbar ist.Production of the contact element or the connector can be carried out more easily and quickly.

Diese Aufgabe wird durch ein elektrisches Kontaktelement mit den Merkmalen des Anspruchs 1, einen Verbinder mit den Merkmalen des Anspruchs 7 und ein Verfahren mit den Merkmalen des Anspruchs 8 gelöst. Bevorzugte Ausführungsformen sind Gegenstand der abhängigen Ansprüche.This object is achieved by an electrical contact element having the features of claim 1, a connector having the features of claim 7 and a method having the features of claim 8. Preferred embodiments are subject of the dependent claims.

Elektrisches Kontaktelement gemäß einem AspektElectrical contact element according to one aspect

Ein Aspekt betrifft ein elektrisches Kontaktelement für einen Steckverbinder gemäß Anspruch 1 aufweisend:

  • einen Leitungskontaktbereich, an welchen eine elektrische Leitung befestigbar ist,
  • einen Steckkontaktbereich, welcher mit einem komplementären Kontaktelement eines komplementären Verbinder elektrisch kontaktierbar ist,
    wobei der Steckkontaktbereich durch Umformen im wesentlichen prismenförmig ausgebildet ist. Erfindungsgemäß ist die Grundfläche des Prismas ein n-Eck mit n ≥ 6, bevorzugt n ≥ 8 und insbesondere n ≥ 12. Vorzugsweise ist n ≤ 24, mehr bevorzugt n ≤ 20, noch bevorzugter n ≤ 16. Beispielsweise ist n = 6, n = 8 oder n = 12.
One aspect relates to an electrical contact element for a connector according to claim 1 having:
  • a line contact area to which an electrical line can be attached,
  • a plug contact area, which can be electrically contacted with a complementary contact element of a complementary connector,
    the plug-in contact area being essentially prism-shaped by reshaping. According to the invention, the base of the prism is an n-gon with n≧6, preferably n≧8 and in particular n≧12. Preferably n≦24, more preferably n≦20, even more preferably n≦16. For example, n=6, n = 8 or n = 12.

Vorteilhafterweise ist das Kontaktelement in einfacher und schneller Weise herstellbar, wobei der Steckkontaktbereich aufgrund der im wesentlichen prismatischen Form eine erhöhte mechanische Festigkeit aufweist.Advantageously, the contact element can be produced easily and quickly, with the plug-in contact area having increased mechanical strength due to the essentially prismatic shape.

Das elektrische Kontaktelement ist aus einem elektrisch leitfähigen Material, insbesondere einem Metall, ausgebildet, wobei ein elektrischer Strom von dem Steckkontaktbereich zum Leitungskontaktbereich fließen kann. Der Leitungskontaktbereich des Kontaktelements ist mit einer zugeordneten elektrischen Leitung elektrisch kontaktierbar bzw. elektrisch verbindbar. Um einen dauerhaften elektrischen Kontakt zwischen elektrischer Leitung und Kontaktelement zu ermöglichen, ist die elektrische Leitung an dem Leitungskontaktbereich lösbar oder unlösbar befestigbar. Entsprechend ist der Steckkontaktbereich mit einem zugeordneten komplementären Kontaktelement des komplementären Verbinders elektrisch bzw. mechanisch kontaktierbar. Daher kann ein elektrischer Strom von der elektrischen Leitung über das Kontaktelement zum komplementären Kontaktelement fließen.The electrical contact element is made of an electrically conductive material, in particular a metal, in which case an electrical current can flow from the plug contact area to the line contact area. The line contact area of the contact element is connected to an associated electrical line electrically contactable or electrically connectable. In order to enable permanent electrical contact between the electrical line and the contact element, the electrical line can be attached to the line contact area in a detachable or non-detachable manner. According to the plug-in contact area with a associated complementary contact element of the complementary connector electrically or mechanically contactable. An electric current can therefore flow from the electric line via the contact element to the complementary contact element.

Der Begriff "Umformen" beschreibt Fertigungsverfahren, in denen der Werkstoff des Kontaktelements, insbesondere ein Metall, plastisch in eine andere Form gebracht wird. Dabei wird ein urgeformtes, beispielsweise ein gegossenes, gerolltes oder gestanztes Vormaterial, das heißt der Vorformling, zu dem endgültigen Kontaktelement geformt. Der Werkstoff behält während des Umformens seine Masse und seinen Zusammenhalt. Dadurch unterscheidet sich ein Umformen im Sinne der Erfindung von einem allgemeinen Verformen des Materials dadurch, daß die Formänderung gezielt herbeigeführt wird, während eine Verformung eine ungezielte elastische oder plastische Formänderung darstellt, beispielsweise beim Verbiegen während des Steckens des Kontaktelements. Weiter wird dem Kontaktelement während des Umformens weder Material hinzugefügt noch abgenommen. Somit umfaßt das Umformen insbesondere keine spanabhebende Bearbeitung, wie beispielsweise drehen, fräsen, schleifen, bohren usw., oder materialhinzufügende Bearbeitung, wie beispielsweise gießen, löten, schweißen, beschichten, anodisches oder kathodisches Abscheiden von Material an der Oberfläche.The term "forming" describes manufacturing processes in which the material of the contact element, in particular a metal, is plastically brought into a different shape. In this case, an originally shaped, for example a cast, rolled or punched starting material, ie the preform, is formed into the final contact element. The material retains its mass and cohesion during forming. As a result, forming within the meaning of the invention differs from a general deformation of the material in that the change in shape is brought about in a targeted manner, while deformation represents an untargeted elastic or plastic change in shape, for example when Bending during insertion of the contact element. Furthermore, neither material is added nor removed from the contact element during the forming process. Thus, forming in particular does not include machining, such as turning, milling, grinding, drilling, etc., or machining to add material, such as casting, soldering, welding, coating, anodic or cathodic deposition of material on the surface.

Der Steckkontaktbereich kann insbesondere durch Druckumformen ausgebildet worden sein. Mit anderen Worten erfolgt das Umformen des Vorformlings bei vorherrschender Druckbeanspruchung. Bevorzugt kann der Steckkontaktbereich durch das Pressen zwischen zwei Gesenken bzw. durch Prägen zwischen Prägestempeln geformt sein. Weiter alternativ könnte der Steckkontaktbereich durch Rollen ausgebildet sein.The plug contact area can in particular have been formed by pressure forming. In other words, the forming of the preform takes place with prevailing compressive stress. The plug contact area can preferably be formed by pressing between two dies or by embossing between embossing dies. Further alternatively, the plug-in contact area could be formed by rolling.

Das Kontaktelement ist einstückig aus elektrisch leitfähigem Material ausgebildet. Beispielsweise kann das Kontaktelement aus einem metallenen Stanzteil (dem Vorformling) ausgebildet sein, welches im Steckbereich umgeformt wurde. Durch die einstückige Ausbildung ist die elektrische Leitfähigkeit innerhalb des Kontaktelements vorteilhafterweise besonders widerstandsarm, da keine Fügestellen existieren, an denen ein Übergangswiderstand auftritt. Auch werden hochfrequente elektrische Signal verzerrungsarm durch das Kontaktelement geleitet. Das Kontaktelement kann insbesondere aus einer Kupfer-Legierung bestehen, beispielsweise einer Kupfer-Zinn-Legierung oder einer Kupfer-NickelLegierung. Zur Verminderung des elektrischen Übergangswiderstands im Leitungskontaktbereich und/oder im Steckkontaktbereich können der Leitungskontaktbereich und/oder der Steckkontaktbereich mit Gold, Silber oder einer Legierung davon beschichtet bzw. plattiert bzw. galvanisiert sein.The contact element is formed in one piece from electrically conductive material. For example, the contact element can be formed from a metal stamped part (the preform), which has been shaped in the plug-in area. Due to the one-piece design, the electrical conductivity within the contact element is advantageously particularly low-resistance, since there are no joints at which a contact resistance occurs. High-frequency electrical signals are also conducted through the contact element with little distortion. The contact element can in particular consist of a copper alloy, for example a copper-tin alloy or a copper-nickel alloy. To reduce the electrical contact resistance in the line contact area and/or in the plug contact area, the line contact area and/or the plug contact area can be coated or plated or galvanized with gold, silver or an alloy thereof.

Vorzugsweise ist der Steckkontaktbereich des Kontaktelements frei von Hohlräumen ausgebildet. Mit anderen Worten kann der umgeformten Steckkontaktbereich massiv ausgebildet sein. Dadurch ergibt sich vorteilhafterweise eine erhöhte mechanische Festigkeit im Steckkontaktbereich verglichen zu anderen Bereichen des Kontaktelements. Insbesondere ist der Steckkontaktbereich nicht als Hohlprisma, sondern als Massivprisma ausgebildet.The plug-in contact area of the contact element is preferably designed to be free of cavities. In other words, the formed plug-in contact area can be solid. This advantageously results in increased mechanical strength in the plug-in contact area compared to other areas of the contact element. In particular, the plug contact area is not designed as a hollow prism but as a solid prism.

Vorzugsweise ist der Steckkontaktbereich des Kontaktelements zumindest bereichsweise linear entlang einer Einführrichtung E in den komplementären Verbinder einführbar. Vorteilhafterweise kann der elektrische Kontakt zwischen dem Kontaktelement und einem komplementären Kontaktelement des komplementären Verbinders durch Stecken des Steckkontaktbereich des Kontaktelements entlang der Einführrichtung E in das komplementäre Kontaktelement erfolgen. Die Einführrichtung E ist insbesondere parallel zur Zylinderachse des im wesentlichen zylindrisch ausgebildeten Steckkontaktbereichs orientiert. Der Steckkontaktbereich weist eine ausreichende Steifigkeit entlang der Einführrichtung E auf, wodurch ein Einführen in das zugeordnete komplementäre Kontaktelement ermöglicht wird. Der Steckkontaktbereich kann einen Durchmesser von etwa 0,5 mm bis etwa 4 mm, bevorzugt von etwa 0,6 mm oder etwa 1 bis etwa 2 mm, aufweisen. Die Längserstreckung des Steckkontaktbereichs kann etwa 3 mm bis etwa 10 mm, bevorzugt etwa 4 mm bis etwa 6 mm betragen.The plug-in contact area of the contact element can preferably be inserted linearly, at least in areas, along an insertion direction E into the complementary connector. Advantageously, the electrical contact between the contact element and a complementary contact element of the complementary connector can be made by plugging the plug-in contact area of the contact element along the insertion direction E into the complementary contact element. The insertion direction E is in particular oriented parallel to the cylinder axis of the essentially cylindrical plug contact area. The plug-in contact area has sufficient rigidity along the insertion direction E, as a result of which insertion into the associated complementary contact element is made possible. The plug contact area can have a diameter of about 0.5 mm to about 4 mm, preferably about 0.6 mm or about 1 to about 2 mm. The length of the plug contact area can be approximately 3 mm to approximately 10 mm, preferably approximately 4 mm to approximately 6 mm.

Der Leitungskontaktbereich ist als Schneidklemmkontakt ausgebildet. Dadurch kann vorteilhafterweise eine elektrische Leitung einfach und zuverlässig mit dem Kontaktelement elektrisch kontaktiert werden. Beispielsweise kann die elektrische Leitung werkzeugfrei mit dem als Schneidklemmkontakt ausgebildeten Leitungskontaktbereich verbunden werden.The line contact area is designed as an insulation displacement contact. As a result, an electrical line can advantageously be electrically contacted with the contact element in a simple and reliable manner. For example, the electrical line can be connected without tools to the line contact area designed as an insulation displacement contact.

Vorzugsweise weist das Kontaktelement weiter zumindest einen Befestigungsbereich auf, mit welchem das Kontaktelement an einem zugeordneten komplementären Befestigungsbereich des Steckverbinders befestigbar ist. Beispielsweise kann der Befestigungsbereich rückstellfähig bzw. federnd ausgebildet sein. Dadurch kann das Kontaktelement nach dem Einführen in eine Kontaktelementaufnahme des Verbinders dort verrasten bzw. verriegeln bzw. mit der Kontaktelementaufnahme derart in Eingriff gelangen, daß das Kontaktelement in der Kontaktelementaufnahme fixiert ist. Der Befestigungsbereich kann einstückig mit dem Kontaktelement ausgebildet sein, beispielsweise durch Stanzen eines Rastelements bzw. eines Vorsprungs.The contact element preferably also has at least one fastening area, with which the contact element can be fastened to an associated, complementary fastening area of the plug connector. For example, the fastening area can be designed to be resilient or springy. As a result, after insertion into a contact element receptacle of the connector, the contact element can latch or lock there or with the contact element receptacle engage in such a way that the contact element is fixed in the contact element receptacle. The fastening area can be formed in one piece with the contact element, for example by stamping a latching element or a projection.

Der Begriff "rückstellfähig verformbar", wie er im Sinne dieser Erfindung verstanden wird, beschreibt, daß der zumindest eine Befestigungsbereich nach einer mechanischen Belastung bzw. elastischen oder plastischen Verformung durch eine Kraft in einer Belastungsrichtung im wesentlichen wieder in die ursprüngliche Form und/oder Lage zurückkehrt. Die mechanische Belastung bzw. Verformung des zumindest einen Befestigungsbereichs erfolgt beispielsweise während des Einführens des Kontaktelement in eine zugeordnete Kontaktelementaufnahme, wodurch mittels der Wandung der Kontaktelementaufnahme eine Kraft in Belastungsrichtung an dem zumindest einen Befestigungsbereich angelegt wird.The term "resiliently deformable" as it is understood in the context of this invention describes that the at least one fastening area essentially returns to its original shape and/or position after mechanical stress or elastic or plastic deformation by a force in a stress direction returns. The mechanical loading or deformation of the at least one fastening area takes place, for example, during the insertion of the contact element into an associated contact element receptacle, as a result of which a force in the loading direction is applied to the at least one fastening area by means of the wall of the contact element receptacle.

Elektrischer Steckverbinder gemäß einem AspektElectrical connector according to one aspect

Ein Aspekt betrifft einen Steckverbinder mit zumindest einem erfindungsgemäßen Kontaktelement. Der Steckverbinder kann einen Kontaktelementhalter zur Aufnahme von zumindest einem Kontaktelement aufweisen. Dazu kann der Kontaktelementhalter für jedes Kontaktelement eine zugeordneten Kontaktelementaufnahme aufweisen, in welche das Kontaktelement zumindest bereichsweise aufgenommen und fixiert ist. Es versteht sich, daß der Steckverbinder zwei, drei, vier, fünf, sechs, sieben, acht, neun, zehn, oder mehr Kontaktelemente aufweisen kann.One aspect relates to a connector with at least one contact element according to the invention. The connector can have a contact element holder for receiving at least one contact element. For this purpose, the contact element holder can have an associated contact element receptacle for each contact element, in which the contact element is accommodated and fixed at least in regions. It goes without saying that the connector can have two, three, four, five, six, seven, eight, nine, ten or more contact elements.

Der Steckverbinder kann ein Gehäuse aufweisen, in welchem der Kontaktelementhalter angeordnet ist. Das Gehäuse kann beispielsweise aus Metall oder Kunststoff ausgebildet sein. Insbesondere kann das Gehäuse aus Zink-Druckguß, Aluminium-Druckguß oder schlagfestem Polyamid bzw. ABS ausgebildet sein. Durch den Kontaktelementhalter kann ein einzelnes oder eine Vielzahl von Kontaktelementen gehalten sein, so daß jedes des Kontaktelemente in ein zugeordnetes Kontaktelement eines komplementären Steckverbinders einsteckbar ist. Dazu können die Kontaktelemente parallel zueinander ausgerichtet sein. Insbesondere sind die Längserstreckungen der Steckkontaktbereiche aller Kontaktelemente parallel zueinander ausgerichtet.The connector can have a housing in which the contact element holder is arranged. The housing can be made of metal or plastic, for example. In particular, the housing can be made of die-cast zinc, die-cast aluminum or impact-resistant polyamide or ABS. A single contact element or a multiplicity of contact elements can be held by the contact element holder, so that each of the contact elements can be inserted into an associated contact element of a complementary plug connector. For this purpose, the contact elements can be aligned parallel to one another. In particular, the longitudinal extensions of the plug-in contact areas of all contact elements are aligned parallel to one another.

Verfahren zum Herstellen eines elektrischen Kontaktelements gemäß einem Aspekt Ein Aspekt betrifft ein Verfahren zum Ausbilden eines einstückigen Kontaktelements gemäß Anspruch 6 die folgenden Schritte:

  • Bereitstellen eines Vorformlings aus einem elektrisch leitfähigen Material mit einem als Schneidklemmkontakt ausgebildeten Leitungskontaktbereich und einem umzuformenden Bereich;
  • Umformen des umzuformenden Bereichs des Vorformlings zu einem im wesentlichen zylindrischen oder prismatischen Steckkontaktbereich.
Method for producing an electrical contact element according to one aspect One aspect relates to a method for forming a one-piece contact element according to claim 6, the following steps:
  • Providing a preform made of an electrically conductive material with a line contact area designed as an insulation displacement contact and an area to be reshaped;
  • Forming the area of the preform to be formed into an essentially cylindrical or prismatic plug-in contact area.

Erfindungsgemäß wird der umzuformende Bereich des Vorformlings derart zu einem im wesentlichen prismatischen Steckkontaktbereich umgeformt, dass der Steckkontaktbereich einen n-eckigen Querschnitt mit n ≥ 6 oder n ≥ 8 oder n ≥ 12 aufweist. Vorzugsweise ist n ≤ 24, mehr bevorzugt n < 20, noch bevorzugter n ≤ 16. Beispielsweise ist n = 6, n = 8 oder n = 12.According to the invention, the area of the preform to be formed is formed into an essentially prismatic plug contact area in such a way that the plug contact area has an n-cornered cross section with n≧6 or n≧8 or n≧12. Preferably n ≤ 24, more preferably n < 20, even more preferably n ≤ 16. For example, n = 6, n = 8 or n = 12.

Vorteilhafterweise ist das Kontaktelement in einfacher Weise durch zwei Bearbeitungsschritte ausbildbar. Als Rohling wird in der Regel ein Metallblech bereitgestellt, aus welchem ein Vorformling ausgestanzt wird. Das Bereitstellen des Vorformlings kann insbesondere ein Stanzen des Vorformlings aus einem Metallblech umfassen. Dieser Stanzschritt ermöglicht eine einfache Massenproduktion der Vorformlinge. Je nach Anforderung an die elektrische Leitfähigkeit können in einfacher Weise unterschiedliche Metallbleche als Rohmaterial bereitgestellt werden. Nach dem Stanzen erfolgt das bereichsweise Umformen des Vorformlings, um den Steckkontaktbereich des Kontaktelements auszubilden.Advantageously, the contact element can be formed in a simple manner using two processing steps. A metal sheet is generally provided as the blank, from which a preform is punched. The provision of the preform can in particular include stamping the preform from a metal sheet. This stamping step enables easy mass production of the preforms. Depending on the electrical conductivity requirements, different metal sheets can be provided as raw material in a simple manner. After punching, this is done in sections Reshaping the preform to form the plug contact area of the contact element.

Vorzugsweise erfolgt das Umformen durch ein Kaltumformen oder ein Warmumformen. Vorteilhafterweise ist das Kaltumformen in effizienter Weise ohne ein Erwärmen des Vorformlings ausführbar.The forming is preferably carried out by cold forming or hot forming. Advantageously, the cold forming can be carried out in an efficient manner without heating the preform.

Bei der Warmumformung wird der Vorformling vor dem Umformen auf eine Temperatur über der Rekristallisationstemperatur des Rohmaterials erwärmt. Dadurch kommt es während der Umformung regelmäßig zur Rekristallisation, die einer Verfestigung des Rohmaterials entgegenwirkt, so daß der Steckkontaktbereich vorteilhafterweise biegsam bzw. verformbar bleibt. Als Kaltumformung wird eine Umformung bezeichnet, bei der der Vorformling im kalten Zustand, beispielsweise bei Raumtemperatur, umgeformt wird, so daß es im Steckkontaktbereich zu einer Verfestigung des Materials kommt.In hot forming, the preform is heated to a temperature above the recrystallization temperature of the raw material before forming. As a result, recrystallization regularly occurs during forming, which counteracts hardening of the raw material, so that the plug-in contact area advantageously remains flexible or deformable. Cold forming refers to a forming in which the preform is formed in the cold state, for example at room temperature, so that the material in the plug-in contact area is solidified.

Vorzugsweise umfaßt das Verfahren den Schritt des Ausbildens zumindest eines Befestigungsbereichs, mit welchem das Kontaktelement an einem komplementären Befestigungsbereich des Steckverbinders befestigbar ist. Der Befestigungsbereich kann einstückig mit dem Kontaktelement, beispielsweise durch Stanzen eines Rastelements bzw. eines Vorsprungs, ausgebildet werden.The method preferably includes the step of forming at least one fastening area, with which the contact element can be fastened to a complementary fastening area of the plug connector. The fastening area can be formed in one piece with the contact element, for example by stamping a latching element or a projection.

Figurenbeschreibungcharacter description

Nachfolgend wird eine bevorzugte Ausführungsform anhand der beigefügten Zeichnungen beispielhaft erläutert. Es zeigt:

Figur 1:
eine perspektivische Ansicht einer Ausführungsform des Kontaktelements;
Figur 2:
eine perspektivische Schnittansicht eines Kontaktelementhalters eines Verbinders mit einer Vielzahl der in Figur 1 gezeigten Kontaktelemente;
Figur 3:
eine perspektivische Ansicht eines ersten Teils eines Verbinders;
Figur 4:
eine perspektivische Ansicht eines zweiten Teils des in der Figur 3 gezeigten Verbinders.
A preferred embodiment is explained below by way of example with reference to the attached drawings. It shows:
Figure 1:
a perspective view of an embodiment of the contact element;
Figure 2:
a perspective sectional view of a contact element holder of a connector with a plurality of in figure 1 shown contact elements;
Figure 3:
a perspective view of a first part of a connector;
Figure 4:
a perspective view of a second part of in the figure 3 connector shown.

Die Figur 1 zeigt eine perspektivische Ansicht einer Ausführungsform eines Kontaktelements 1 mit einem Leitungskontaktbereich 3, einem Steckkontaktbereich 5 und einem Befestigungsbereich 7. Der Leitungskontaktbereich 3 ist als Schneidklemmkontakt ausgebildet, um eine elektrische Leitung eines Kabels 29 (in Figur 4 gezeigt) elektrisch zu kontaktieren.the figure 1 shows a perspective view of an embodiment of a contact element 1 with a line contact area 3, a plug-in contact area 5 and a fastening area 7. The line contact area 3 is designed as an insulation displacement contact in order to connect an electrical line of a cable 29 (in figure 4 shown) electrically closed to contact.

Der als Schneidklemmkontakt ausgebildete Leitungskontaktbereich 3 erlaubt vorteilhafterweise eine einfache und zuverlässige elektrische Kontaktierung der elektrischen Leitung. Dadurch kann die elektrische Leitung insbesondere werkzeugfrei mit dem Kontaktelement 1 elektrisch kontaktiert werden, wodurch das Kontaktelement 1 vorteilhafterweise in feldkonfektionierbaren Verbindern verwendbar ist.The line contact area 3 designed as an insulation displacement contact advantageously allows simple and reliable electrical contacting of the electrical line. As a result, the electrical line can be electrically contacted with the contact element 1 in particular without tools, as a result of which the contact element 1 can advantageously be used in connectors that can be assembled in the field.

Der Steckkontaktbereich 5 ist im wesentlichen prismenförmig ausgebildet, wobei die Grundfläche des in der Figur 1 gezeigten Prismas ein Achteck darstellt. Es versteht sich, daß auch Prismen vorgesehen sein können, welche ein Sechseck, ein Zehneck, ein Zwölfeck oder ein Polygon mit einer höheren Eckzahl als zwölf aufweist. Längsachse A des Prismas, welches den Steckkontaktbereich 5 ausbildet, ist parallel zu einer Einführrichtung E orientiert, entlang welcher das Kontaktelement 1 zumindest bereichsweise in einen komplementären Verbinder (nicht gezeigt) einführbar ist, um das Kontaktelement 1 mit einem komplementären Kontaktelement des komplementären Verbinders elektrisch zu verbinden.The plug-in contact area 5 is essentially prism-shaped, with the base of the in the figure 1 the prism shown represents an octagon. It goes without saying that prisms can also be provided which have a hexagon, a decagon, a dodecagon or a polygon with a number of corners greater than twelve. The longitudinal axis A of the prism, which forms the plug-in contact area 5, is oriented parallel to an insertion direction E, along which the contact element 1 can be inserted at least in some areas into a complementary connector (not shown) in order to electrically connect the contact element 1 to a complementary contact element of the complementary connector associate.

Der Begriff "im wesentlichen prismenförmig" umschreibt, daß der Steckkontaktbereich 5 geringe Abweichungen von der Prismenform aufweisen kann, wie beispielsweise eine abgerundete Stirnfläche 5a, welche insbesondere in Richtung der Einführrichtung E konisch bzw. spitz zulaufen kann, um ein Einführen des Kontaktelements 1 in das komplementäre Kontaktelement zu erleichtern. Des Weiteren kann der Steckkontaktbereich 5 entlang einer Dickenrichtung D, welche im wesentlichen senkrecht zur Einführrichtung E steht, oder entlang einer Breitenrichtung B, welche ebenfalls im wesentlichen senkrecht zur Einführrichtung E steht, eine Abweichung von einer Solldicke bzw. einer Sollbreite bis etwa 10%, bevorzugt etwa 5% aufweisen. Das Kontaktelement 1 kann bevorzugt bereichsweise eine größere Breitenerstreckung entlang der Breitenrichtung B aufweisen als die Dickenerstreckung entlang der Dickenrichtung D ist, insbesondere im Bereich des Leitungskontaktbereichs 3.The term "substantially prismatic" describes that the plug contact area 5 can have slight deviations from the prism shape, such as a rounded end face 5a, which can taper conically or pointedly in the direction of insertion E in order to facilitate insertion of the contact element 1 into the to facilitate complementary contact element. Furthermore, the plug contact area 5 can deviate from a target thickness or a target width of up to about 10% along a thickness direction D, which is essentially perpendicular to the insertion direction E, or along a width direction B, which is also essentially perpendicular to the insertion direction E. preferably about 5% exhibit. The contact element 1 can preferably have a greater width extension in the width direction B in some areas than the thickness extension in the thickness direction D, in particular in the area of the line contact area 3.

Der Befestigungsbereich 7 des Kontaktelements 1 kann ein rückstellfähig verformbares Rastelement 7a aufweisen, mit welchem das Kontaktelement 1 in einer Kontaktelementaufnahme eines Verbinders (in der Figur 2 gezeigt) befestigt werden kann. Aufgrund der rückstellfähigen Verformbarkeit des Rastelements 7a führt eine mechanische Belastung des Rastelements 7a entlang einer Belastungsrichtung B' zu einer Verformung bzw. Verlagerung des Rastelements 7a. Sobald die mechanische Belastung entlang der Belastungsrichtung B' entfällt, kehrt das Rastelement 7a im wesentlichen wieder in die ursprüngliche Form und/oder Lage zurück. Insbesondere umfaßt eine rückstellfähige Verformbarkeit eine elastische Verformbarkeit. Zusätzlich kann der Befestigungsbereich 7 ein Eingriffelement 7b aufweisen, welches ausgelegt ist, mit einem komplementären Eingriffelement der Kontaktelementaufnahme (in Figur 2 gezeigt) in Eingriff zu gelangen, um eine Verlagerung des Kontaktelements 1 innerhalb der Kontaktelementaufnahme zu hemmen. Bei der in der Figur 1 gezeigten Ausführungsform weist das Eingriffelement 7b einen sich entlang der Einführrichtung E verjüngenden Abschnitt auf, an dem sich entgegen der Einführrichtung E eine Hinterschneidung befindet. In die Hinterschneidung kann beispielsweise Material der Kontaktelementaufnahme durch ein plastisches und/oder elastisches Verlagern dringen, um mit dem Eingriffelement 7b in Reibschluß bzw. Formschluß zu gelangen.The fastening area 7 of the contact element 1 can have a resiliently deformable latching element 7a, with which the contact element 1 can be locked in a contact element receptacle of a connector (in the figure 2 shown) can be attached. Due to the resilient deformability of the latching element 7a, a mechanical load on the latching element 7a along a loading direction B′ leads to a deformation or displacement of the latching element 7a. As soon as the mechanical stress along the stress direction B' ceases, the latching element 7a essentially returns to its original shape and/or position. In particular, resilient deformability includes elastic deformability. In addition, the fastening area 7 can have an engagement element 7b, which is designed to engage with a complementary engagement element of the contact element receptacle (in figure 2 shown) to engage to inhibit displacement of the contact element 1 within the contact element receptacle. At the in the figure 1 The embodiment shown has the engagement element 7b along the direction of insertion E tapering section on which opposite to the direction of insertion E is an undercut. Material of the contact element receptacle, for example, can penetrate into the undercut by plastic and/or elastic displacement in order to frictionally or positively engage with the engagement element 7b.

Die in der Figur 1 gezeigte Ausführungsform des Kontaktelements 1 ist einstückig ausgebildet. In einem beispielhaften Herstellungsverfahren wird ein Metallblech bereitgestellt, aus welchem ein Vorformling ausgestanzt wird. Dabei wird das Stanzwerkzeug entlang der Dickenrichtung D bewegt, um den Vorformling aus dem Metallblech herauszustanzen. Folglich ist die beim Stanzen erzeugte Stanzkante 9 parallel zur Dickenrichtung orientiert. Während des Stanzens können der Schneidklemmkontakt 3 sowie das Eingriffelement 7d ausgebildet werden. Optional kann der Vorformling bereichsweise gebogen werden, beispielsweise um das Rastelement 7a des Befestigungsbereichs 7 auszubilden. Des Weiteren kann der Vorformling weitere Biegebereiche 9a aufweisen, wobei das Biegen gleichzeitig mit oder nach dem Stanzen ausgeführt werden kann.The one in the figure 1 shown embodiment of the contact element 1 is integrally formed. In an exemplary manufacturing method, a metal sheet is provided, from which a preform is stamped. In this case, the punching tool is moved along the thickness direction D to remove the preform from the punching out sheet metal. Consequently, the punched edge 9 produced during punching is oriented parallel to the thickness direction. The insulation displacement contact 3 and the engagement element 7d can be formed during the stamping. Optionally, the preform can be bent in certain areas, for example in order to form the latching element 7a of the fastening area 7 . Furthermore, the preform can have further bending areas 9a, in which case the bending can be carried out simultaneously with or after the stamping.

Durch ein bereichsweises Umformen des Vorformlings wird der Steckkontaktbereich 5 geformt bzw. ausgebildet. Das Umformen erfolgt in einem Fertigungsschritt, in welchem das Material des Vorformlings bereichsweise plastisch in eine andere Form gebracht wird. Dadurch wird die Stanzkante 9 im umgeformten Steckkontaktbereich 5 in der Regel derart umgeformt, daß die Stanzkante 9 als solche nicht mehr erkennbar ist. Während der Querschnitt des Vorformlings in einer Fläche, welche senkrecht zur Einführrichtung E steht, im wesentlichen rechteckig geformt ist, ist der Querschnitt des umgeformten Steckkontaktbereichs 5 des Kontaktelements 1 im wesentlichen ein Polygon bzw. n-Eck mit n größer als fünf. Beispielsweise kann der Steckkontaktbereich 5 einen sechseckigen, einen achteckigen oder ein zwölfeckigen Querschnitt aufweisen. Durch das Umformen des Vorformlings entsteht das Kontaktelement 1.The plug contact area 5 is shaped or formed by area-wise reshaping of the preform. The forming takes place in a production step in which the material of the preform is plastically brought into a different shape in some areas. As a result, the stamped edge 9 is generally formed in the formed plug contact area 5 in such a way that the stamped edge 9 can no longer be recognized as such. While the cross section of the preform is essentially rectangular in a surface that is perpendicular to the insertion direction E, the cross section of the formed plug contact area 5 of the contact element 1 is essentially a polygon or n-corner with n greater than five. For example, the plug contact area 5 can have a hexagonal, an octagonal or a dodecagonal cross section. The contact element 1 is formed by forming the preform.

Das plastische Umformen ist materialerhaltend, so daß der Vorformling und das Kontaktelement 1 eine identische Masse aufweisen. Das Umformen kann in einfacher Weise mittels Prägewerkzeugen bzw. Gesenken (Obergesenk und Untergesenk) durchgeführt werden, wobei zwischen den Prägewerkzeugen bzw. den Gesenken eine Negativform des auszubildenden Steckkontaktbereichs 5 ausgebildet ist. Zum Umformen des Vorformlings wird dieser zumindest bereichsweise in die Umformwerkzeuge, d.h. die Prägewerkzeuge oder Gesenke, eingeführt und anschließend mittels der Umformwerkzeuge mit Druck beaufschlagt, wodurch sich das Material des Vorformlings umformt, um die in den Umformwerkzeugen ausgebildete Negativform auszufüllen und dadurch die gewünschte Form anzunehmen. Dadurch unterscheidet sich das Umformen insbesondere von einer spanabhebenden Bearbeitung wie beispielsweise einem Drehen, bei welchem dem Vorformling Material abgenommen wird, um die gewünschte zylindrische Form zu erreichen. Da im Gegensatz zu einer spanabhebenden Bearbeitung das Material des Vorformlings im Bereich des Steckkontaktbereichs 5 erhalten bleibt, kann der Vorformling in diesem Bereich weniger Material aufweisen, um eine gewünschte Endstärke des Steckkontaktbereichs 5 des Kontaktelements 1 zu erreichen. Es versteht sich, daß das plastische Umformen des Vorformlings sowohl als Kaltumformen als auch als Warmumformen durchgeführt werden kann. Vorteilshafterweise erlaubt das Kaltumformen des Vorformlings eine schnellere Bearbeitung, da es nicht notwendig ist, den Vorformling zu erwärmen. Gleichzeitig erhöht sich beim Kaltumformen die Festigkeit im umgeformten Bereich, also in Steckkontaktbereich 5 des Kontaktelements. Dadurch weist das Kontaktelement 1 im Bereich des Steckkontaktbereichs 5 eine höhere Festigkeit auf, so daß der Steckkontaktbereich 5 während eines Steckens stärker mechanisch belastbar ist. Dagegen wird die Zähigkeit durch das Kaltumformen verringert. Ist eine Verringerung der Zähigkeit nicht gewünscht, so kann das Umformen alternativ als Warmumformen erfolgen.The plastic forming is material-preserving, so that the preform and the contact element 1 have an identical mass. The forming can be carried out in a simple manner by means of embossing tools or dies (upper die and lower die), a negative form of the plug contact area 5 to be formed being formed between the embossing tools or dies. To shape the preform, it is inserted at least in certain areas into the forming tools, i.e. the embossing tools or dies, and then pressure is applied by means of the forming tools, as a result of which the material of the preform is shaped in order to fill the negative mold formed in the forming tools and thereby assume the desired shape . This distinguishes the forming in particular from a machining, such as turning, in which material is removed from the preform to achieve the desired cylindrical shape. Since, in contrast to machining, the material of the preform remains in the area of the plug contact area 5, the preform can have less material in this area in order to achieve a desired final thickness of the plug contact area 5 of the contact element 1. It goes without saying that the plastic forming of the preform can be carried out both as cold forming and as hot forming. Advantageously, the cold forming of the preform allows faster processing since it is not necessary to heat the preform. At the same time, cold forming increases the strength in the formed area, ie in plug contact area 5 of the contact element. As a result, the contact element 1 has greater strength in the area of the plug-in contact area 5, so that the plug-in contact area 5 can withstand greater mechanical loads during plugging. On the other hand, toughness is reduced by cold forming. If a reduction in toughness is not desired, forming can alternatively be carried out as hot forming.

Um gute elektrische Leitungseigenschaften des Kontaktelements 1 zu erreichen, kann das Kontaktelement 1 insbesondere aus einem Metallblech geformt werden, welches aus einer Kupferlegierung, beispielsweise einer Kupferzinnlegierung oder einer Kupfernickellegierung, besteht. Die Auswahl der Legierung des Kontaktelements 1 erfolgt aufgrund der notwendigen mechanischen und elektrischen Eigenschaften des Kontaktelements 1. Zur Verbesserung des elektrischen Übergangswiderstandes kann das Kontaktelement 1 zumindest bereichsweise mit Gold, Silber oder einer Goldsilberlegierung plattiert bzw. galvanisiert werden. Dadurch wird vorteilhafterweise auch eine Korrosion des Kontaktelements 1 an den plattierten bzw. galvanisierten Bereichen vermieden.In order to achieve good electrical conduction properties of the contact element 1, the contact element 1 can be formed in particular from a metal sheet which consists of a copper alloy, for example a copper-tin alloy or a copper-nickel alloy. The alloy of the contact element 1 is selected on the basis of the necessary mechanical and electrical properties of the contact element 1. To improve the electrical contact resistance, the contact element 1 can be plated or galvanized at least in areas with gold, silver or a gold-silver alloy. This advantageously also prevents corrosion of the contact element 1 on the plated or galvanized areas.

Die Figur 2 zeigt eine perspektivische Schnittansicht eines Kontaktelementhalters 11, welcher eine Vielzahl von Kontaktelementaufnahmen 13 aufweist, in welche jeweils ein zugeordnetes Kontaktelement 1 angeordnet und befestigt ist. Der Kontaktelementhalter 11 ist aus einem elektrisch isolierenden Material ausgebildet, vorzugsweise einem Kunststoff, wie beispielsweise Polyamid, ABS, Polybutylenterephthalat (PBT) oder Polycarbonat. Um den Kontaktelementhalter 11 mit den Kontaktelementen zu bestücken, in der in Figur 2 gezeigten Ausführungsform werden acht Kontaktelemente 1 durch den Kontaktelementhalter 11 gehalten, stehen zwei Optionen zur Verfügung.the figure 2 shows a perspective sectional view of a contact element holder 11, which has a plurality of contact element receptacles 13, in each of which an associated contact element 1 is arranged and fastened. the Contact element holder 11 is formed from an electrically insulating material, preferably a plastic such as polyamide, ABS, polybutylene terephthalate (PBT) or polycarbonate. In order to equip the contact element holder 11 with the contact elements in the figure 2 embodiment shown, eight contact elements 1 are held by the contact element holder 11, two options are available.

Zum ersten kann der Kontaktelementhalter 11 bereitgestellt werden, beispielsweise als Spritzgußteil aus einem thermoplastischen Kunststoff ausgebildet werden. In dem Körper des Kontaktelementhalters 11 ist eine den aufzunehmenden Kontaktelementen 1 entsprechende Anzahl von Kontaktelementaufnahmen 13 ausgebildet. In jede der Kontaktelementaufnahmen 13 kann ein zugeordneten Kontaktelement 1 entlang der zweiten Einführrichtung E' eingeführt werden, um das Kontaktelement 1 in den Kontaktelementhalter 11 anzuordnen. Durch das Einführen des Kontaktelements 1 in die Kontaktelementaufnahme 13 kann das Eingriffelement 7b des Kontaktelements 1 mit der Wandung der Kontaktelementaufnahme in Eingriff bzw. Reibschluß gelangen. Dadurch wird ein Verlagern des Kontaktelements 1 relativ zum Kontaktelementhalter 11 entgegen der zweiten Einführrichtung E' gehemmt. Des Weiteren kann durch das Einführen des Kontaktelements 1 in die Kontaktelementaufnahme 13 die Wandung der Kontaktelementaufnahme 13 in mechanischen Kontakt mit dem rückstellfähig verformbaren Rastelement 7a treten, wobei das Rastelement 7a entlang der Belastungsrichtung B' verformt wird. Die Wandung der Kontaktelementaufnahme 13 kann eine Ausnehmung in der Wandung 13a als bevorzugtes komplementäres Rastelement 13a aufweisen, so daß das Rastelement 7a in das komplementäre Rastelement 13a eingreifen kann, wenn das Kontaktelement 1 derart entlang der zweiten Einführrichtung E' in die Kontaktelementaufnahme 13 eingeführt ist, daß eine vorbestimmte Anordenposition erreicht ist. In der Anordenposition erfolgt eine Verlagerung des Rastelements 7a aufgrund der rückstellfähigen Verformbarkeit des Rastelements 7a entgegen der Belastungsrichtung B', so daß es zu einem Eingreifen bzw. Verriegeln des Rastelements 7a mit dem komplementären Rastelement 13a kommt. Mit anderen Worten ist das Kontaktelement 1 in der Anordenposition innerhalb der Kontaktelementaufnahme 13 fixiert.Firstly, the contact element holder 11 can be provided, for example in the form of an injection molded part made of a thermoplastic material. A number of contact element receptacles 13 corresponding to the contact elements 1 to be received are formed in the body of the contact element holder 11 . An associated contact element 1 can be inserted into each of the contact element receptacles 13 along the second insertion direction E′ in order to arrange the contact element 1 in the contact element holder 11 . By inserting the contact element 1 into the contact element receptacle 13, the engagement element 7b of the contact element 1 can engage or frictionally engage with the wall of the contact element receptacle. This prevents the contact element 1 from being displaced relative to the contact element holder 11 counter to the second insertion direction E′. Furthermore, by inserting the contact element 1 into the contact element receptacle 13, the wall of the contact element receptacle 13 can come into mechanical contact with the resiliently deformable latching element 7a, with the latching element 7a being deformed along the loading direction B′. The wall of the contact element receptacle 13 can have a recess in the wall 13a as a preferred complementary latching element 13a, so that the latching element 7a can engage in the complementary latching element 13a when the contact element 1 is inserted into the contact element receptacle 13 along the second insertion direction E' in such a way that that a predetermined arranging position is reached. In the arrangement position, the latching element 7a is displaced against the loading direction B' due to the resilient deformability of the latching element 7a, so that the latching element 7a engages or locks with the complementary latching element 13a. With others In other words, the contact element 1 is fixed in the arrangement position within the contact element receptacle 13 .

Als zweite Option kann der Kontaktelementhalter 11 um eine Vielzahl von bereitgestellten Kontaktelementen 1 herum ausgebildet werden. Beispielsweise kann der Kontaktelementhalter 11 als ein Spritzgußteil aus einem thermoplastischen Elastomer oder thermoplastischen Polymer ausgebildet werden, wenn eine Vielzahl von Kontaktelementen 1 mittels einer Haltevorrichtung (nicht gezeigt) in Position gehalten wird, so daß sich zwischen dem Kontaktelementhalter 11 und den Kontaktelementen 1 eine innige Verbindung ergibt. Dadurch sind die Kontaktelemente 1 unlösbar mit dem Kontaktelementhalter 11 verbunden. Die Kontaktelementaufnahmen 13 entsprechen dann den Lücken im Material des Kontaktelementhalters 11, welche durch das Vorhandensein der Kontaktelemente 1 bedingt sind.As a second option, the contact element holder 11 can be formed around a plurality of contact elements 1 provided. For example, the contact element holder 11 can be formed as an injection molded part from a thermoplastic elastomer or thermoplastic polymer if a plurality of contact elements 1 are held in position by means of a holding device (not shown), so that there is an intimate connection between the contact element holder 11 and the contact elements 1 results. As a result, the contact elements 1 are permanently connected to the contact element holder 11 . The contact element receptacles 13 then correspond to the gaps in the material of the contact element holder 11, which are caused by the presence of the contact elements 1.

Wie in der Figur 2 gezeigt, können die Kontaktelemente 1 entlang einer Kreislinie in dem Kontaktelementhalter 11 angeordnet sein. Dabei können die Kontaktelemente 1 und insbesondere die Rastelemente 7a derart angeordnet sein, daß die Belastungsrichtung B' für alle Kontaktelemente 1 radial nach außen oder nach innen orientiert ist. Mit anderen Worten kann der Kontaktelementhalter 11 achsensymmetrisch um eine Symmetrieachse ausgebildet sein, wobei die Symmetrieachse bevorzugt parallel zur Einführrichtung E orientiert ist.Like in the figure 2 shown, the contact elements 1 can be arranged along a circular line in the contact element holder 11 . The contact elements 1 and in particular the latching elements 7a can be arranged in such a way that the loading direction B' for all contact elements 1 is oriented radially outwards or inwards. In other words, the contact element holder 11 can be designed to be axially symmetrical about an axis of symmetry, with the axis of symmetry preferably being oriented parallel to the insertion direction E.

Die Figur 3 zeigt eine perspektivische Ansicht eines ersten Teils 15 eines Verbinders mit einem in der Figur 2 gezeigten Kontaktelementhalter 11. Der Kontaktelementhalter 11 ist in einem Gehäuse 17 angeordnet, welches bevorzugt aus Metall oder schlagfestem Kunststoff besteht. Das Gehäuse 17 des ersten Teils des Verbinders 15 weist eine Anschlußkonfiguration 17a auf, welche es ermöglicht, eine zweiten Teil 19 des Verbinders entlang einer dritten Einführrichtung E" zumindest bereichsweise in das Gehäuse 17 des ersten Teils 15 des Verbinders einzuführen.the figure 3 shows a perspective view of a first part 15 of a connector with a in the figure 2 shown contact element holder 11. The contact element holder 11 is arranged in a housing 17, which is preferably made of metal or impact-resistant plastic. The housing 17 of the first part of the connector 15 has a connection configuration 17a, which enables a second part 19 of the connector to be inserted at least in regions along a third insertion direction E" into the housing 17 of the first part 15 of the connector.

Die Figur 4 zeigt eine perspektivische Ansicht des zweiten Teils 19 des Verbinders mit einem Gehäuse 21, welches eine komplementäre Anschlußkonfiguration 21a aufweist, welche mit der Anschlußkonfiguration 17a in Eingriff bringbar ist. Insbesondere können die Anschlußkonfiguration 17a und die komplementäre Anschlußkonfiguration 21a miteinander verschraubt werden. Das Gehäuse 21 kann ebenfalls aus Metall oder schlagfestem Kunststoff ausgebildet sein.the figure 4 Figure 1 shows a perspective view of the second part 19 of the connector with a housing 21 having a complementary terminal configuration 21a engageable with the terminal configuration 17a. In particular, the connection configuration 17a and the complementary connection configuration 21a can be screwed together. The housing 21 can also be made of metal or impact-resistant plastic.

Der zweite Teil 19 des Verbinders weist ferner einen Leitungshalter 23 auf, in welchem eine Vielzahl von Leitungsaufnahmen 25 ausgebildet ist. Die Leitungsaufnahmen 25 sind ausgelegt, jeweils eine zugeordnete elektrische Leitung 27 zumindest bereichsweise aufzunehmen. Die elektrischen Leitungen 27 sind Bestandteil eines Kabels 29, welches entlang einer vierten Einführrichtung E‴ durch eine Durchtrittsöffnung des Gehäuses 21 des zweiten Teils 19 des Verbinders hindurchgeführt ist, wobei die Ummantelung des Kabels 29 zumindest im Bereich des Leitungshalters 23 entfernt ist, um die elektrischen Leitungen 27 entlang einer Spreizrichtung S, welche im wesentlichen senkrecht zur vierten Einführrichtung E‴ orientiert ist, radial nach außen abzuspreizen bzw. umzubiegen, damit die elektrischen Leitungen in jeweils einer zugeordneten Leitungsaufnahme 25 aufgenommen werden kann. Das Kabel 29 kann mittels der Zugentlastung 31 an dem Gehäuse 21 befestigt werden. Insbesondere kann die Zugentlastung 31 als PG Verschraubung ausgeführt sein.The second part 19 of the connector also has a line holder 23 in which a multiplicity of line receptacles 25 are formed. The line receptacles 25 are designed to each accommodate an associated electrical line 27 at least in certain areas. The electrical lines 27 are part of a cable 29, which is guided along a fourth insertion direction E‴ through a passage opening in the housing 21 of the second part 19 of the connector, the sheathing of the cable 29 being removed at least in the area of the line holder 23 in order to allow the electrical Lines 27 along a spreading direction S, which is oriented substantially perpendicular to the fourth insertion direction E‴, to spread or bend radially outwards, so that the electrical lines can each be accommodated in an associated line receptacle 25 . The cable 29 can be attached to the housing 21 by means of the strain relief 31 . In particular, the strain relief 31 can be designed as a PG screw connection.

Durch eine Einführen des zweiten Teils 19 des Verbinders mit dem daran angeordneten Kabel 29 entlang der dritten Einführrichtung Eʺ in den ersten Teil 15 des Verbinders gelangt die Anschlußkonfiguration 17a in Eingriff mit der komplementären Anschlußkonfiguration 21a, so daß beide Verbinderteile 15, 19 miteinander verbunden werden können. Gleichzeitig werden die Schneidklemmkontakte 3 des ersten Teils 15 des Verbinders entgegen der dritten Einführrichtung Eʺ in den zugeordneten Schneidklemmkontakteaufnahmen 25a der Leitungsaufnahme 25 aufgenommen, wodurch die elektrischen Leitungen 27, welche sich in den Leitungsaufnahmen 25 befinden, durch die zugeordneten Schneidklemmkontakte 3 geschnitten und elektrisch kontaktiert werden. Mit anderen Worten erfolgt die elektrische und mechanische Verbindung beider Teile 15, 19, des Verbinders durch ein Zusammenstecken des zweiten Teils 19 und des ersten Teils 15 des Verbinders entlang der dritten Einführrichtung E". Nach dem Zusammenfügen beider Teile 15, 19 des Verbinders sind das Kabel 29 und der Verbinder miteinander elektrisch und mechanisch verbunden, das Kabel 29 mithin konfektioniert. Der Verbinder kann insbesondere als ein Steckverbinder ausgebildet sein, welcher entlang einer Einführrichtung E in einen komplementären Verbinder (nicht gezeigt) eingesteckt werden kann, um das Kabel 29 mit einer weiteren elektrischen Einrichtung zu kontaktieren. Insbesondere kann es sich bei dem Steckverbinder um einen M12 Verbinder handeln, welcher ausgelegt ist, eine Ethernet-Verbindung gemäß Kategorie 6A (CAT 6A) herzustellen. Der in den Figuren gezeigte Steckverbinder ist vorteilhafterweise feldkonfektionierbar. Mit anderen Worten kann ein Kabel 29 im Feld, d.h. am Einsatzort ohne Spezialwerkzeug, konfektioniert werden. Mithin ist lediglich ein Messer bzw. eine Abisolierzange notwendig, um den Isoliermantel des Kabels 29 bereichsweise zu entfernen und die überstehenden Teile der in den Leitungsaufnahmen 25 angeordneten elektrischen Leitungen 27 abzuschneiden. Die anschließende elektrische Kontaktierung und Befestigung des Verbinders mit den elektrischen Leitungen 27 des Kabels 29 erfolgt dann werkzeuglos.By inserting the second part 19 of the connector with the cable 29 arranged thereon along the third insertion direction Eʺ into the first part 15 of the connector, the connection configuration 17a engages with the complementary connection configuration 21a, so that both connector parts 15, 19 can be connected to one another . At the same time, the insulation displacement contacts 3 of the first part 15 of the connector are received in the associated insulation displacement contact receptacles 25a of the line receptacle 25 counter to the third insertion direction Eʺ, as a result of which the electrical lines 27, which are in the line receptacles 25, are cut through the associated insulation displacement contacts 3 and electrically contacted . With others In other words, the electrical and mechanical connection of the two parts 15, 19 of the connector takes place by plugging the second part 19 and the first part 15 of the connector together along the third insertion direction E". After the two parts 15, 19 of the connector have been joined together, the cable 29 and the connector are electrically and mechanically connected to each other, thus assembling the cable 29. The connector can be designed in particular as a plug connector, which can be plugged into a complementary connector (not shown) along an insertion direction E in order to connect the cable 29 to a further electrical In particular, the connector can be an M12 connector, which is designed to establish an Ethernet connection according to category 6 A (CAT 6 A ).The connector shown in the figures can advantageously be assembled in the field a cable 29 in the field, ie at the site without Spezia oil tool, to be assembled. Consequently, only a knife or stripping pliers is required to remove the insulating jacket of the cable 29 in certain areas and to cut off the protruding parts of the electrical lines 27 arranged in the line receptacles 25 . The subsequent electrical contacting and attachment of the connector to the electrical lines 27 of the cable 29 then takes place without tools.

Bevorzugt ist die zweite Einführrichtung E' parallel zur Einführrichtung E orientiert. Weiter bevorzugt ist die dritte Einführrichtung E" parallel zur zweiten Einführrichtung E', besonders bevorzugt auch zur Einführrichtung E, orientiert. Weiter bevorzugt ist die vierte Einführrichtung E'" parallel zur dritten Einführrichtung E", besonders bevorzugt auch zur zweiten Einführrichtung E', orientiert. Insbesondere können die vier Einführrichtungen E, E', Eʺ und E‴ gemeinsam parallel zueinander orientiert bzw. identisch sein.The second insertion direction E′ is preferably oriented parallel to the insertion direction E. The third insertion direction E" is more preferably oriented parallel to the second insertion direction E', particularly preferably also to the insertion direction E. More preferably, the fourth insertion direction E'" is oriented parallel to the third insertion direction E", particularly preferably also to the second insertion direction E' In particular, the four insertion directions E, E′, E″ and E‴ can be oriented parallel to one another or be identical.

BezugszeichenlisteReference List

11
Kontaktelementcontact element
33
Leitungskontaktbereich / SchneidklemmkontaktLine contact area / insulation displacement contact
55
Steckkontaktbereichplug contact area
5a5a
Stirnflächeface
77
Befestigungsbereichmounting area
7a7a
Rastelementlocking element
7b7b
Eingriffelementengagement element
99
Stanzkantepunching edge
9a9a
Biegebereichbending range
1111
Kontaktelementhaltercontact element holder
1313
Kontaktelementaufnahmecontact element recording
1515
erster Teil eines Verbindersfirst part of a connector
1717
Gehäusehousing
17a17a
Anschlußkonfigurationport configuration
1919
zweiter Teil des Verbinderssecond part of the connector
2121
Gehäusehousing
21a21a
komplementäre Anschlußkonfigurationcomplementary port configuration
2323
Leitungshalterline holder
2525
Leitungsaufnahmeline pickup
25a25a
SchneidklemmkontaktaufnahmeInsulation displacement contact recording
2727
elektrische Leitungelectrical line
2929
Kabelcable
3131
Zugentlastungstrain relief
AA
Längsachselongitudinal axis
BB
Breitenrichtunglatitude direction
B'B'
Belastungsrichtungload direction
DD
Dickenrichtungthickness direction
EE
Einführrichtunginsertion direction
E'E'
zweite Einführrichtungsecond insertion direction
EʺEʺ
dritte Einführrichtungthird direction of insertion
E‴E‴
vierte Einführrichtungfourth direction of insertion
SS
Spreizrichtungspreading direction

Claims (8)

  1. An electrical contact element (1) for a plug-in connector, having:
    - a line contact region (3) to which an electrical line (27) can be fastened,
    - a plug-in contact region (5) that can be electrically contacted with a complementary contact element of a complementary connector,
    wherein the contact element (1) is formed as a single part of an electrically conductive material; and the line contact region (3) is formed as an insulation displacement contact,
    characterized in that:
    the plug-in contact region (5) is formed by being formed into a substantially prismatic shape and has an n-corner cross-section with n ≥ 6 or n ≥ 8 or n ≥ 12, wherein the forming is a production method in which a change in shape of a preform is brought about in a targeted manner while retaining its mass.
  2. The contact element (1) according to claim 1, wherein the plug-in contact region (5) of the contact element (1) is formed free of cavities.
  3. The contact element (1) according to one of the preceding claims, wherein the plug-in contact region (5) of the contact element (1) can be inserted at least regionally in a linear manner along an insertion direction (E) into the complementary connector.
  4. The contact element (1) according to one of the preceding claims, moreover having at least one fastening region (7), by means of which the contact element (1) can be fastened to an associated complementary fastening region (13) of the plug-connector.
  5. A plug-in connector having:
    at least one contact element (1) according to one of the preceding claims.
  6. A method for forming a single-part contact element (1), comprising:
    - providing a preform consisting of an electrically conductive material with a line contact region (3) formed as an insulation displacement contact and a region to be formed, wherein
    the region of the preform to be formed is formed by being formed into a substantially prismatic plug-in contact region (5) such that the plug-in contact region (5) has an n-corner cross-section with n ≥ 6 or n ≥ 8 or n ≥ 12, wherein the forming is a production method in which a change in shape of the preform is brought about in a targeted manner while retaining its mass.
  7. The method according to claim 6, wherein the forming comprises cold forming or hot forming.
  8. The method according to one of claims 6 or 7, further comprising the step:
    - forming at least one fastening region (7), by means of which the contact element (1) can be fastened to a complementary fastening region (13) of the plug-connector.
EP14003492.7A 2013-10-10 2014-10-10 Electrical contact element, connector and manufacturing method Active EP2860829B1 (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
DE201310016814 DE102013016814A1 (en) 2013-10-10 2013-10-10 Electrical contact element, connectors and manufacturing process

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EP2860829A1 EP2860829A1 (en) 2015-04-15
EP2860829B1 true EP2860829B1 (en) 2022-04-06

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Application Number Title Priority Date Filing Date
EP14003492.7A Active EP2860829B1 (en) 2013-10-10 2014-10-10 Electrical contact element, connector and manufacturing method

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EP (1) EP2860829B1 (en)
DE (1) DE102013016814A1 (en)

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE202018104958U1 (en) 2018-08-30 2018-09-12 Harting Electric Gmbh & Co. Kg Connector with components of improved material

Citations (2)

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Publication number Priority date Publication date Assignee Title
US3071844A (en) * 1959-08-05 1963-01-08 Malco Mfg Co Method of making a terminal
DE20208436U1 (en) * 2002-05-31 2002-09-19 Harting Electric Gmbh & Co Kg One-piece contact element

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Publication number Priority date Publication date Assignee Title
US4434552A (en) * 1982-03-01 1984-03-06 The Bendix Corporation Method of making a pin type electrical connector contact
US4969839A (en) * 1983-05-13 1990-11-13 Dill Products Incorporated Electrical connector
DE3733380C2 (en) * 1987-10-02 1997-08-14 Merten Gmbh & Co Kg Geb Electrical plug or coupling socket
JP2003036911A (en) * 2001-02-13 2003-02-07 Yazaki Corp Male type terminal fitting
ES1049361Y (en) * 2001-06-01 2002-04-16 Lear Automotive Eeds Spain PERFECTED MALE TERMINAL FOR SIDE INSERTION CONNECTOR.
DE10323615A1 (en) * 2003-05-26 2004-12-23 Hirschmann Electronics Gmbh & Co. Kg Contact element and complementary line chamber for a plug or socket using insulation displacement technology
US7713100B2 (en) * 2005-07-21 2010-05-11 Fci Male electrical terminal with a twisted contact section
JP4734136B2 (en) * 2006-02-16 2011-07-27 株式会社オートネットワーク技術研究所 Terminal fitting and method of manufacturing terminal fitting
US7976353B2 (en) * 2006-09-29 2011-07-12 Tyco Electronics Corporation Two-piece electrical terminal
JP4747119B2 (en) * 2007-03-07 2011-08-17 ホシデン株式会社 Manufacturing method of pin contact
DE112008002761A5 (en) * 2007-08-13 2010-07-15 Michael Taller Flush-molded connector pin
DE102011103327A1 (en) * 2011-05-27 2012-11-29 Mc Technology Gmbh Contact pin for contact elements of plug connector for cable, has preset portion in which bore extending in axial direction of contact pin is formed

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US3071844A (en) * 1959-08-05 1963-01-08 Malco Mfg Co Method of making a terminal
DE20208436U1 (en) * 2002-05-31 2002-09-19 Harting Electric Gmbh & Co Kg One-piece contact element

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EP2860829A1 (en) 2015-04-15

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