DE102007023636B4 - Lamp cap for an electric lamp and method for producing a lamp cap - Google Patents

Abstract

arrangement for connecting a power consumer to a voltage source, in which in a housing made of insulating material a Contact device is arranged on the one hand to the voltage source leading electrical conductor and on the other hand, the power consumers electrically conductive connected are and in which the contact means of two from each other separate parts, which are embedded in a housing filling body made of a plastic are and stand out from the same, by electrically conductive additions electrically conductive is.

Description

Technical area

The The invention is based on a lamp base for an electric lamp, preferably for a motor vehicle lamp made of a plastic base part and at least one in the plastic base part provided contact device for the power supply having.

State of the art

In the publication DE 196 16 409 A1 For example, an electric lamp with a base made of an electrically insulating material is known. The led out of the lamp bulb power supply lines are welded in the interior of the connection region of the base with formed as a contact lugs electrical connections. The interior, by the contact lugs and the power supply lines are welded together, is sealed by a cover part. The disadvantage of such a lamp base of the complex manufacturing process and the high cost of avoiding leaks problems.

In the document DE 198 55 412 A1 are integrally formed tabs provided with an L-shaped profile, wherein one leg of the contact lug is welded to the power supply lines and the other leg protrudes into the connection area. 1 shows such a contact lug 112 that have a contact section 110 on a leg and a connecting portion 114 has on the other leg. In such a contact lug, the problem is lack of tightness, since the contact flags without additional treatment have a low adhesion to the plastic base material of the lamp cap and because the plastic material and the material of the contact lugs have very different coefficients of expansion. Furthermore, the good thermal conductivity of the contact lug 112 disadvantageous, wherein from the junction with the power supply lines at the connecting portion 114 for electrical contact with the plug on the contact portion 110 a heat transfer takes place through which no more permissible temperatures can arise in the contact area of the lamp cap.

at another solution in the prior art is in integrally formed contact lugs in the lamp base a cavity provided after the encapsulation of the contact lugs with the plastic material of the lamp base with liquid silicone filled and is heated up. Although lets thereby eliminating the problem of detention, but is an additional Manufacturing step after forming contact lug and lamp base necessary.

From the publication DE 10 2005 048 446 A1 An arrangement is known for connecting a glass cap lamp to a voltage source, in which the power supply wires of the glass cap lamp and the conductors to the voltage source are incorporated directly into a plastic with a filler.

In the document EP 0 570 991 A2 is a lamp socket for receiving a Glassockellampe disclosed. Contact elements made of an electrically conductive plastic material are on the one hand with contact wires of the glass block lamp and in conjunction and on the other hand can be in communication with a conductor leading to the voltage source.

Presentation of the invention

The Object of the present invention is to provide a lamp base and to provide a method for producing this lamp cap, at which adhesion problems between the plastic material of the lamp cap and the metal material of a contact device as well as tightness problems are eliminated.

These Task is governed by the objects of claims 1, 3 and 14 solved.

Especially advantageous embodiments can be found in the dependent claims.

According to the invention is for solution the task of an arrangement for connecting a power consumer provided with a voltage source, in which in an insulating material existing housing a contact element is arranged, on the one hand to the voltage source leading electrical Head and on the other hand, the power consumers are electrically connected, and wherein the contact element consists of two separate ones There is parts that are embedded in a housing filling the body made of a plastic and protrude from the same, by electrical conductive additives electrical conductive is. The invention is preferred in connector applications aligned, in which electrical conductors are umhlt and then certain requirement for the tightness and low heat conduction over the met electrical conductor become. The arrangement for connecting a power consumer with A voltage source is preferably a lamp cap for an electrical Lamp, preferably a motor vehicle lamp.

The invention further relates to a lamp base for an electric lamp, preferably a motor vehicle lamp having a plastic base part and at least one provided in the plastic base part contact means for the power supply. The contact device has two Kon Contact elements which are connected to one another via an at least partially provided in the plastic base part connecting means having plastic, which is added to the electrical line at least one filler. This can be a Lampenso ckel that meets high sealing requirements, implemented. In addition, due to the function of the contact device as a thermal brake before a low temperature at outwardly guided portions of the contact element.

It is preferred if the plastic unreinforced and / or reinforced thermoplastics has, whereby the manufacturing cost of the contact device low is.

When Plastic has become polyamide 6 due to the variability of its Properties, due to additives and proved to be advantageous due to the low production costs.

The filler is preferably metallic or ceramic and may comprise copper, aluminum, steel or Al ₂ O ₃ , whereby a sufficient conductivity can be produced.

Of the filler is preferably provided in the form of fibers, chips, splinters and / or platelets, because they are distributed in the contact device in a simple manner let and allow a high electrical conductivity.

The Connecting device preferably has a solder, in particular Soft solder on so that between the connecting device on the one hand and the metal of the contact elements on the other hand a adequate approach can be implemented.

When Lot is preferred to a solder with 8% tin and 92% zinc, as the thermal and electrical properties the function of the connection device support.

The Contact elements are preferably made of metal and can sections be coated with a primer. In this way, the electrical loss during power transmission to the power guidewires of the Lamp be kept low and in addition the contact elements be securely held in the connecting device.

It Furthermore, a method for producing a lamp cap for an electrical A lamp comprising the steps of: providing two contact elements, Connecting the two contact elements via a connection device, having the plastic, the at least for electrical conduction a filler is added and forming a plastic base part at least at a portion of the connecting device. This can be done a simple manufacturing process with good adhesion and sealing behavior between contact element and plastic base part with simultaneous effect implement the connecting device as a thermal brake.

In a preferred embodiment The two contact elements are produced by punching, whereby a simple manufacturing process is feasible.

Further can the two contact elements over the connecting device by encapsulation of the contact elements get connected. This allows a provision of the connecting device and the plastic base part with little manufacturing effort.

The Plastic base part is preferred at the connection device formed by encapsulation. In this way are conventional Manufacturing processes for Before seeing a plastic base part of contact lugs also when Subject of the present invention usable.

Brief description of the drawings

in the Below, the invention will be explained in more detail with reference to an embodiment. The Figures show:

1 a side view of a contact lug according to the prior art,

2 3 is a schematic sectional side view of a lamp cap with lamp inserted according to the present invention;

3 a sectional side view of a plastic base part without lamp vessel and holder according to the present invention,

4 a plan view of a portion of a punching strip according to the present invention,

5 a top view of a punching strip according to the prior art,

6 a test arrangement for determining the voltage drop below the current in the case of electrically conductive plastics according to the present invention,

7 graphical representations of the voltage drop below temperature over the current for metal vanes with a test arrangement accordingly 6 ,

Preferred embodiment of invention

2 shows a lamp assembly according to the invention 1 with schematically illustrated lamp base 2 ,

The lamp base 2 has a plastic base part 4 with a connection section 6 on. The connection section 6 is designed like a bush. In the interior 8th of the connection section 6 is a contact element 10 a contact device 12 in front. The contact device 12 is substantially L-shaped and has a connecting element 14 that with power supply wires 16 . 18 the lamp 20 are connectable. The section of the contact device 12 to which the contact element 10 with the connecting element 14 is connected in the plastic base part 4 cast.

Right-angled to the interior 8th is on the plastic base part 4 a flange portion 22 provided, over which the lamp base 2 at an in 2 dashed reflector shown 24 over a sealing ring 26 is fastened. Radially inside the flange section 22 is in the lamp base 2 a connection room 28 provided in which the connecting element 14 the contact flag 12 protrudes. In the flange section 22 is also an annular support sleeve 30 anchored, preferably by ultrasonic welding, in which is an intermediate ring 32 a cup-shaped holding part 34 supported in which the bruise 36 a lamp vessel 38 the lamp 20 is included. On to the bruise 36 opposite end portion of the lamp vessel 38 is a light-absorbing coating 40 intended.

In the 2 illustrated filament 42 is with the power supply wires 16 . 18 electrically connected.

In the preferred embodiment of the invention, the lamp is 20 a single-filament halogen incandescent lamp, which is intended for use in a motor vehicle headlight. The lamp base 2 is preferably of the types H8, H9 or H11, which can be used in particular for high beam and fog lights.

In 3 is a sectional view of the plastic base part 4 with incorporated contacting device 12 in the interior 8th and the connection room 28 protrudes, shown.

The connection room 28 is in the flange section 22 is formed and is in relation to the interior 8th of the connection section 6 of the lamp socket 2 formed in a vertical direction. Between the interior 8th and the connection room 28 there is a body section 5 the plastic base part, which is solid and in which a connecting device 60 the contact device 12 is provided.

The contact device 12 also has the contact element 10 that in the interior 8th protrudes, and the connecting element 14 that in the connection room 28 protrudes, up. On the connecting element 14 is a groove to the side from which the lamp vessel is attachable to the lamp base 46 provided for introducing the power supply of the lamp vessel. The groove 46 is through two bars 48 . 50 limits the inclines to the side of the groove 48a . 50a have to facilitate the introduction of the power supply lines.

The contact element 10 and the connecting element 14 are preferably punched parts. Unlike the in 5 In the prior art, in which V-shaped profile sections are provided, are in the present invention, as in 4 shown, profile sections 54 with respective leg sections 54a . 54b provided, the separate legs of the V-shaped profile of 5 form. These profile sections 54a . 54b are in the body section in such a way 5 the plastic base part provided that the imaginary vertices of the profile sections 54a . 54b furthest into the body section 5 protrude. In this way, a secure attachment of the contact device 12 secured in the plastic base part.

The contact element 10 and the connecting element 14 indicate to the interior 8th or in the connection room 28 opposite end portions recesses 56 . 58 on, through which the contact element 10 and the connecting element 14 in the connection device 60 are anchored.

The connection device 60 is preferably a highly filled material, in particular a plastic with metallic or ceramic fillers. By the connecting device is an age-resistant and cohesive bond between the contact element 10 and the connecting element 14 produced while allowing the electrical line. For this purpose, the connecting device 60 a plastic, such as unreinforced or reinforced thermoplastics such. PA6, PA66, PBP. These plastics are accompanied by a filler, preferably a metallic or ceramic filler having the exemplary geometries of fibers, chips, chips or platelets. As the material, copper, aluminum, steel or AL ₂ O _{3 are} preferred.

For the cohesive bond between connecting device 60 and contact element 10 as well as connecting element 14 are solders in the Plastic introduced, preferably soft solders such. As tin solder, good results were achieved with a solder with 8% tin and 92% zinc. Other solders, such. B. other soft solders for aluminum according to DIN 1707 D are possible.

To the adhesion between the connecting device 60 and contact element 10 as well as connecting element 14 can improve the contact element 10 and the connecting element 14 be coated with a primer.

In the production, the contact device according to the invention means 12 with the connection device 60 no significant additional effort, since the contact lugs are now punched in two parts and the gap between the contact element 10 and the connecting element 14 with the electrically conductive plastic of the connecting device 60 and then in a further step, the prefabricated contact lug with contact element 10 , Connecting device 60 and connecting element 14 with the material of the plastic base part 4 is overmoulded. In this way, it is not necessary that there is an additional Dichtverguss as in the prior art.

Furthermore, the connecting device acts 60 as a thermal brake, wherein the connecting element 14 to the contact element 10 only a very small heat transfer takes place.

By eliminating Dichtverguss the costs can be reduced and by the temperature reduction on the connecting element 14 can implement compact connector with advantageous thermal properties.

Depending on the requirements of the contact device 12 can connect devices 60 be implemented with different compositions of the plastic, the filler and the solder and different dimensions are implemented in dependence on mechanical requirements and electrical requirements.

The 6 and 7 are to be taken a measuring arrangement and measurement results for electrically conductive plastics for power transmission.

In 6 is a top metal banner 70 and a lower metal banner 72 shown, between which the connecting device 74 made of electrically conductive plastic. In the present arrangement, the connecting device 74 a copper-solder compound based on polyamide 6 between the metal flags 70 . 74 was introduced, pressed and then heated to 240 °. Through this process, it was possible to use the flowing plastic matrix of the connecting device 74 A sufficient approximation between the compound and the metal can be achieved, so that an electrical contact between the two metal lugs 70 . 72 is possible.

The upper metal banner 70 is with a connection of a power supply 76 connected while the other terminal of the power supply 76 via a load consumer 78 with the lower metal flag 72 connected is. It follows a temperature measurement in the connecting device 74 and a voltage drop measurement between the upper metal tab 70 and the lower metal flag 72 , 7 can the measurement results at layer thickness of the connecting device 74 of 0.4 mm, on the one hand, for a longitudinal flow direction, as represented by squares, and on the other hand, in a transverse flow direction, as represented by circles.

From the diagram of 7 It can be seen that the voltage drop was below 60 mV even at 10 amperes in both a transverse and a longitudinal flow direction. The temperature in both cases was below 90 ° C even at a current of 10 amperes.

In this way, it has been demonstrated by the inventors that the contact device according to the invention allows a constant transfer of currents up to several amperes, without material damage as a result of heating the connecting device 60 comes.

Claims (17)

Arrangement for connecting a power consumer with a voltage source, in which in one of insulating material existing housing one Contact device is arranged on the one hand to the voltage source leading electrical conductor and on the other hand, the power consumers electrically conductive connected are and in which the contact means of two from each other separate parts, which are embedded in a housing filling body made of a plastic are and stand out from the same, by electrically conductive additions electrically conductive is. Arrangement according to claim 1, wherein the power consumer an electric vehicle lamp is. Lamp base ( 2 ) for an electric lamp having a plastic base part ( 4 ) and at least one provided in the plastic base part contact device ( 12 ) for the power supply, wherein the contact device ( 12 ) two contact elements ( 10 . 14 ), which via an at least partially in the plastic base part ( 4 ) provided connection Facility ( 60 ) are joined together, the plastic, which is added to the electrical line at least one filler. A lamp cap according to claim 3, wherein the electrical Lamp is a motor vehicle lamp. A lamp cap according to claim 3, wherein the plastic unreinforced and / or reinforced Thermoplastics has. A lamp cap according to claim 3, wherein the plastic Polyamide 6 has. A lamp cap according to any one of claims 3 to 6, wherein the filler metallic or ceramic. A lamp cap according to any one of claims 3 to 7, wherein the filler Copper, aluminum, steel or has. A lamp cap according to any one of claims 3 to 8, wherein the filler in the form of fibers, chips, Splinters and / or platelets is present. Lamp cap according to one of claims 3 to 9, wherein the connecting device ( 60 ) has a solder, preferably a soft solder. A lamp base according to claim 10, wherein the solder is 8% Tin and 92% zinc. Lamp cap according to one of claims 3 to 9, wherein the contact elements ( 10 . 14 ) are made of metal. Lamp cap according to one of claims 3 to 9, wherein the contact elements ( 10 . 14 ) are at least partially coated with a primer. Method for producing a lamp cap ( 2 ) for an electric lamp, comprising the steps of: providing two contact elements ( 10 . 14 ), Connecting the two contact elements ( 10 . 14 ) via a connection device ( 60 ) comprising plastic, to which at least one filler is added for electrical conduction, and forming a plastic base part ( 4 ) at least at a portion of the connecting device ( 60 ). The method of claim 14, wherein the two contact elements ( 10 . 14 ) are produced by punching. Method according to claim 14 or 15, wherein the two contact elements ( 10 . 14 ) via the connection device ( 60 ) are connected by molding over the contact elements. Method according to one of claims 14 to 16, wherein the plastic base part ( 4 ) at the connection device ( 60 ) is formed by overmolding.