EP2425492B1 - Electrical plug-and-socket device - Google Patents

Description

The invention relates to an electrical plug-in device for effecting an electrical connection by plugging with a mating plug device, with a housing, with at least one electrical contact element having a first end connected to an electrical lead, which comprises an insulating jacket, and a second end leading in the plug-in direction which is mounted in the housing and perpendicular to the insertion direction under the action of the system of an electrical counter-contact element of the mating plug device is displaced.

Such a plug-in device is known from the REMA Lipprandt GmbH & Co. KG, Bonn and is referred to as "plug-in device with flat contacts". Thus, the over-insertion and disconnection with the mating device is possible, the contacts are movably mounted within the housing. For this purpose, a leaf spring is anchored in the housing for each contact against the spring force, the contacts are moved in the direction perpendicular to the insertion direction during the insertion process and thus cause a spring-loaded interaction of the contacts and mating contacts. The mobility of the contacts in the housing is chosen so large that the contacts are plugged over a counter contact directed survey. Such elevations are provided in particular in order to avoid electrical contact resistances a defined contact surface to accomplish. Assign contact and mating contact respectively facing each other surveys, this is additionally achieved by a locking force that must be overcome when disconnecting plug and mating device.

• mechanischen Eigenschaften der elektrischen Zuleitung;
• Art der Verbindung der elektrischen Zuleitung mit dem elektrischen Kontaktelement;
• relative Lage der Zuleitung zum elektrischen Kontaktelement;
• Abnutzungsgrad der elektrischen Steckvorrichtung, insbesondere abhängig vom Alter und der mechanischen Beanspruchung der Steckvorrichtung.

Such plug devices are already in use for a long time. It has been shown that the force that has to be applied for plugging or separating plug-in device and mating device varies greatly and is not always reproducible even with brand new plugs. This phenomenon will probably be related to the fact that this force is dependent on a variety of parameters, for example

• mechanical properties of the electrical supply line;
• Type of connection of the electrical supply line with the electrical contact element;
• relative position of the supply line to the electrical contact element;
• Degree of wear of the electrical plug-in device, in particular depending on the age and the mechanical stress of the plug-in device.

The movement of the electrical contact elements in the housing leads to wear of the bearing seats and to an increase in the game with increasing duration and amount of stress.

Furthermore, it was found in the past that, surprisingly, in individual cases, all plugs of an entire vehicle fleet were subject to increased wear. This phenomenon is explained by the fact that a mating connector, such as a charger mating connector, due to manufacturing and processing tolerances electrical contact elements having properties that have a particularly wear-promoting effect. It has been tried in the past, to reduce this problem by minimizing processing tolerance using specialized processing tools.

In addition, in these known plug-in devices with flat contacts of disadvantage that acting on the electrical leads strain relief reduces the mobility of the electrical contact elements, which significantly complicates the Übersteck- or separation process in such plug devices. If the strain relief to avoid the above disadvantage is dispensed with, there are special problems, since such plug devices are often separated by pulling on the cables: The force required for separation then acts almost directly on the contacts, bends them possibly as well as to effect the electrical contact existing leaf springs, with the result that a secure electrical contact is no longer guaranteed. By then occurring electrical contact resistance there is a risk that the plug-in device is thermally destroyed, in the worst case even on fire. In addition, such contact problems can be caused by manufacturing tolerances of the various components, if they add up unfavorably, Also, the contact shape after pressing the connector with the associated cable can be changed negatively. so that processing tolerances can be added to the manufacturing tolerances.

A generic electrical connector is from the EP 1 152 495 A1 known. The housing of this electrical connector is integrally formed.

The US 2009/011657 A1 describes an electrical connector and an electrical contact element thereof. It is wave-shaped to be elastically deformable. As the material of the electrical contact element, inter alia brass, bronze and copper alloys are specified. Also the US 2008/0011396 A1 discloses a copper alloy having particularly good bending properties and mechanical strength for use as electrical contact elements.

From the GB 2,232,017 a pre-assembled with connection cables lamp holder is known.

The DE 100 34 502 A1 relates to an electrical connector, which is provided in particular for proximity switches. It comprises a contact carrier on which a union nut is rotatably arranged.

The invention is therefore an object of the invention to provide a generic electrical connector, which is variable.

This object is achieved by the reproduced in claim 1 electrical connector.

According to the invention, in this electrical plug connection, the at least one electrical contact element is made of a material which allows the displacement approximately perpendicular to the plugging direction under the action of the electrical mating plug element under elastic deformation.

Surprisingly, it has been found that it is possible to use electrical contact elements with high electrical conductivity and good electrical contact properties with an elastic compliance, which allows a plug-in with mating contact elements, without the need for the electrical contact elements to be movably mounted in the housing and without this supporting spring elements are necessary. Manufacturing tolerances are thereby reduced.

In order to adapt the electrical connector according to the invention to different, existing mating plug devices in the sense of a plug-in, the plug-in device according to the invention has a mating face, which is formed by an attachable to the housing essay. It can then for different mating devices always the same arrangement comprising the electrical contact elements with welded electrical Supply lines and the housing are used, which is then provided with the appropriate attachment.

To attach the attachment to the housing, the housing and attachment may include compatible latching devices.

Experiments have shown that as a material in particular bronze alloys, copper beryllium alloys or electrolyte-copper alloys come into consideration when they have - very particularly preferably - obtained by mechanical influences (cold working) sufficient elastic properties.

In order to increase the elastic force, under which the contacts abut against the mating contacts, the attachment may have a projection directed to the respective contact element, against which the respective electrical contact element bears with its counter contact element facing side under spring tension.

Since it is no longer necessary due to the elastic deformability of the electrical contact elements to store them movably in the housing, the housing in the particularly preferred embodiment, a storage area in which the electrical contact element is mounted rigidly in the region of the first end.

The manufacturability of the electrical plug-in device according to the invention is facilitated and the contact reliability between the electrical contact element and the lead connected to it are improved - if, as is particularly preferred - the electrical lead is welded to the first end of the contact element. As a result of this measure, only lower processing tolerances are produced in comparison to pressing.

Very particular preference is then given to a development of the electrical plug-in device according to the invention, in which the storage area by encapsulation of the first end portion connected to the electrical supply line with housing material is manufactured, since thus completely eliminates the formation of a storage area in the housing and thus the manufacturing cost is reduced.

A particularly tight fit of the contacts and the electrical leads welded thereto is achieved during encapsulation, when the housing material and the material of the insulating jacket are matched to one another such that during encapsulation of a cohesive connection of the materials is formed. It is hereby achieved an extremely effective strain relief, which also allows a separation caused by means of this plug-in connector by pulling on the cable without damaging the connector. In addition, the plug device housing thus formed is particularly resistant to breakage and even suitable to complete the connection region between the electrical supply line and the electrical contact element gas-tight.

However, it is also possible to provide the housing and the attachment with mutually cooperating abutment surfaces, which allow a cohesive connection, for example by gluing or welding.

In order to improve the electrical contact between the electrical contact element and the electrical mating contact element and to provide a force to overcome when disconnecting plug and mating device, also have the electrical contact elements of the plug-in device according to the invention in the region of the second end directed towards the mating contact element survey ,

Very preferred is an embodiment of the electrical plug-in device according to the invention, in which two copies of the same, rotated in the insertion direction by 180 °, can be plugged. This electrical plug-in device can thus act as a counter-plug device, in other words at the same time form plug and socket part.

Fig. 1

einen vertikalen Längsschnitt dieser Steckvorrichtung gemäß Schnittlinie I-I in Fig. 2 sowie

Fig. 2

einen horizontalen Längsschnitt gemäß Schnittlinie II-II in Fig. 1.

In the drawing, an embodiment of the plug-in device according to the invention is shown schematically. It shows:

Fig. 1

a vertical longitudinal section of this connector according to section line II in Fig. 2 such as

Fig. 2

a horizontal longitudinal section along section line II-II in Fig. 1 ,

The plug-in device, designated as a whole by 100, comprises two electrical contact elements 1, 2, which are produced by cutting to length and bending from a flat strand of material.

The illustrated in the drawing on the right, first ends 7, 8 of the electrical contact elements 1, 2 are each electrically and mechanically connected to an electrical conductor 5, 6 of an electrical supply line 3, 4 by welding. The electrical leads 3, 4 have insulating shells 9, 10, which has been removed for the purpose of welding over a length L of the electrical conductors 5, 6.

The first ends 7, 8 of the electrical contact elements 1, 2, the stripped length L and in the direction of the electrical leads 3, 4 subsequent length I of the insulating shells 9, 10 are molded with an insulating plastic material form fit to a housing 11. This plastic material forming the housing 11 and the material of the insulating sheaths 9, 10 are matched to one another such that the insulating sheaths 9, 10 additionally enter into a cohesive connection with the housing 11 over the length I.

At the first, firmly anchored in the housing 11 ends 7, 8 of the electrical contact elements 1, 2 are substantially flat areas 12, 13, which in each case a directed to a counter contact element, not shown in the drawing elevation 14, 15 pass. At the elevations 14, 15, the contact surfaces to form the counter-contact elements, not shown in the drawing, close in accordance Fig. 1 downwardly directed portions, the second, free ends 16, 17 of the electrical contact elements 1, 2 form.

In order for the electrical contact elements 1, 2 to be able to yield in this existing mating contact elements when being plugged with a mating plug device not shown in the drawing, and a reliable contact with the mating contact elements is ensured, the electrical contact elements 1, 2 are of electrically highly conductive material having such elastic properties manufactured, which allows a resilient displacement of the elevations 14, 15 over the length F. Suitable materials having these properties are, in particular, copper alloys such as bronze, copper beryllium or electrolytic copper having a Brinell hardness of> HRW 130.

The electrical plug-in device 100 further comprises an attachment 18 which completely surrounds the electrical contact elements 1, 2, with the exception of the side leading in the direction of insertion, which is shown on the left in the drawing, which forms the mating face of the electrical plug-in device. On the side facing the housing 11, the attachment 18 has a collar 19, the contour of which is adapted to a flange 20 provided on the housing 11 such that the collar 19 sits on the flange 20 at least substantially free of play.

The housing 11 and the attachment 18 have compatible locking devices 21 which secure the attachment 18 against removal from the housing 11. Alternatively or additionally, the mutually facing surfaces of the collar 19 and the flange 20 can be materially connected to each other, for example by gluing, so as to accomplish a more reliable connection of attachment 18 and housing 11. By this measure, various essays 18 whose mating face are adapted to different mating plug devices, held and, if necessary, connected to the arrangement consisting of electrical contact elements, housing and electrical conductors.

In order to increase the electrical contact safety, the electrical contact elements 1, 2 rest under a higher elastic force on mating contact elements, the article 18 has a respective electrical contact element 1, 2 directed projection 22, to which the respective electrical contact element 1, 2 bears with its counter contact element facing side under spring tension.

LIST OF REFERENCE NUMBERS

100

plug-in device

1

Electrical contact element

2

Electrical contact element

3

Electrical supply

4

Electrical supply

5

Electrical conductor

6

Electrical conductor

7

first end

8th

first end

9

Insulating coat

10

Insulating coat

11

casing

12

level area

13

level area

14

survey

15

survey

16

second end

17

second end

18

essay

19

collar

20

flange

21

locking devices

22

head Start

23

storage area

F

length

I

length

L

length

Claims (14)

1. Electrical plug and socket connector (100) for establishing an electrical connection by being plugged into a mating connector,
   comprising a casing (11),
   comprising at least one electrical contact element (1, 2), having a first end (7, 8) connected to an electrical supply line (3, 4) that comprises an insulating sheath (9, 10), and a second end (16, 17) leading in the plug-in direction, which contact element is mounted in the casing (11) and can be moved perpendicularly to the plug-in direction under the action of applying an electrical mating contact element of the mating connector,
   the electrical contact element (1, 2) being made of a material which allows the movement under the action of the electrical mating contact element by elastic deformation,
   characterized in that
   the plug and socket connector (100) comprises a connector face, which is formed by an attachment (18) fastened to the casing (1).
2. Plug and socket connector according to claim 1, characterized in that the casing (11) and the attachment (18) comprise mutually compatible engaging means (21).
3. Plug and socket connector according to claim 2, characterized in that the casing (11) and the attachment (18) comprise interacting contact surfaces, which allow an integral bond.
4. Plug and socket connector according to any of claims 1 to 3, characterized in that the attachment (18) comprises a projection (22) oriented towards the particular contact element (1, 2), against which projection the side of the particular electrical contact element (1, 2) facing the mating contact element is applied under spring pretension.
5. Plug and socket connector according to any of claims 1 to 4, characterized in that the material is a bronze alloy.
6. Plug and socket connector according to any of claims 1 to 4, characterized in that the material is a copper beryllium alloy.
7. Plug and socket connector according to any of claims 1 to 4, characterized in that the material is an electrolyte copper alloy.
8. Plug and socket connector according to any of claims 1 to 7, characterized in that the material is cold-worked.
9. Plug and socket connector according to any of claims 1 to 8, characterized in that the casing (11) comprises a mounting region (23), by means of which the electrical contact element (1, 2) is rigidly mounted in the casing (11) in the region of the first end (7, 8).
10. Plug and socket connector according to any of claims 1 to 9, characterized in that the electrical supply line (3, 4) is welded to the first end (7, 8) of the contact element (1, 2).
11. Plug and socket connector according to any of claims 1 to 10, characterized in that the mounting region (23) is produced by encapsulating the first end region (7, 8) connected to the electrical supply line (3, 4) with casing material.
12. Plug and socket connector according to claim 11, characterized in that the material of the casing (11) and the material of the insulating sheathing (9, 10) are matched such that the materials are integrally bonded during the encapsulation.
13. Plug and socket connector according to any of claims 1 to 12, characterized in that the electrical contact element (1, 2) comprises a bulge (14, 15) oriented towards the mating contact element in the region of the second end (16, 17).
14. Plug and socket connector according to any of claims 1 to 13, characterized in that the plug and socket connector (100) and the mating connector are formed identically such that two plug and socket connectors (100) can be plugged in, in the plug-in direction, so as to be rotated by 180°.

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