DE102021211016B3 - connector - Google Patents

Abstract

The invention relates to a connector (1), the connector (1) having an inner contact part (2) extending along an axial direction (A) for receiving a mating contact element (20) and an outer spring part (3), the outer spring part (3) being outside of the contact inner part (2) is arranged transversely to the axial direction (A) with respect to a radial direction (R), the contact inner part (2) being predominantly made of a first material (M1), the spring outer part (3) being predominantly made of a second material (M2) is formed, wherein the contact inner part (2) and the spring outer part (3) are formed from a single sheet (5) as a stamped and bent part, the shear modulus of the second material (M2) being at least 1.5 times of the shear modulus of the first material (M1) and/or wherein the modulus of elasticity of the second material (M2) is at least 1.5 times the modulus of elasticity of the first material (M1).

Description

field of invention

The invention relates to a connector.

State of the art

Electrical connectors for receiving a mating contact element are known from the prior art. Such connectors can be constructed in one piece, ie made from a metal band (usually made of a copper alloy) or sheet metal by stamping and bending. One-piece contacts made of copper alloys have comparatively low primary holding forces in a contact chamber, a higher risk of plastic deformation during the mating process and a tendency to relaxation (depending on the alloy) which causes the normal contact forces to decrease over time and temperature, with the risk of premature contact interruption . Such a one-piece connector is from DE 10 2007 040 937 B3 known.

Alternatively, two-part contacts are also known. An outer spring part (also referred to as an overspring or outer contact box) is made of steel as a single element and slipped over an inner contact part (also referred to as a contact box) made separately from another metal sheet and made of an electrically highly conductive material such as copper. In this way, the primary holding force in a contact chamber can be increased, since this is now applied by the separate contact outer part made of steel. Furthermore, the overspring made of steel enables a force support of the contact lamella. Such a two-part manufactured and then assembled connector, which consists of a contact inner part and one of which is initially separately manufactured outer spring part, is from DE 102 48 809 A1 known.

From the DE 10 2011 005 655 A1 a contact element is known with an element section on the contact point side and with an element section on the connection side facing away therefrom, the element section on the contact point side and the element section on the connection side consisting of two different, materially bonded materials.

From the JP S64 - 60 979 A a box-shaped contact element is known which has a base designed as a contact surface made of a highly conductive material and two side walls designed as holding arms made of a spring material, the contact element being formed in one piece from a single substrate.

From the DE 14 40 860 A a composite metal strip made of different alloys for electrical connection parts is known.

From the EP 0 645 843 A2 a method for producing a contact element is known, in which first two materials are connected to one another by a lamination step and then a contact element is formed from the laminate created in this way in a stamping and bending process.

From the DE 11 2014 000 872 T5 there is known an electrical connection structure comprising a copper member and a metal member connected to the copper member. The electrical connection structure further includes a waterproof layer formed at least in a portion of the copper member other than a connection portion connected to the metal member. In order to prevent electrical corrosion, it is provided that the surface treatment layer comprises a surface treatment agent whose molecular structure has a hydrophobic part and a chelate group.

Disclosure of Invention

The invention is based on the finding that in order to improve the mechanical properties of plug-in connectors that are manufactured in one piece and that should also have high electrical conductivity, it is necessary, for example, to use thicker sheet metal or special copper alloys. These alloys are intended to increase the modulus of elasticity and/or the shear modulus of the soft and ductile copper to such an extent that the necessary primary holding forces are achieved with a small sheet thickness and the contact normal force that the contact lamellas exert on an inserted mating contact element is also achieved and maintained over the service life . However, the use of thicker sheet metal is often not possible due to the dimensions required for the connectors. In turn, using high-performance copper alloys is more expensive than using normal copper or simple copper alloys.

Two-piece contacts are more complex and expensive to manufacture, since a separate stamping and bending tool is required to produce the outer spring part or the overspring and the two parts (inner contact part and outer spring part) that were initially manufactured separately still have to be assembled together after they have been manufactured. In addition, the possibility of miniaturization of such two-part contacts can be restricted at some points due to the doubling of the material.

There may therefore be a need to provide a connector that satisfies high mechanical requirements for primary retention forces in a contact chamber in which the connector is accommodated, which satisfies permanently high mechanical requirements for the contact normal force relative to a mating contact element inserted into the connector, and which in a simple and inexpensive manufacturing process can be produced. Furthermore, it may be desirable for the connector to have high electrical conductivity in current-carrying sections.

Advantages of the Invention

This need can be met by the subject matter of the present invention according to the independent claim. Advantageous embodiments of the present invention are described in the dependent claims.

According to the invention, a connector is proposed.

The plug connector has an inner contact part, which extends along an axial direction, for receiving a mating contact element, and an outer spring part, which can also be referred to as the outer contact part. The outer spring part or outer contact part is arranged outside of the inner contact part with respect to a radial direction that extends transversely to the axial direction, the inner contact part being predominantly formed from a first material, the outer spring part or the outer contact part being predominantly formed from a second material. It is provided that the inner contact part and the outer spring part are formed from a single sheet metal as a stamped and bent part. The shear modulus of the second material is at least 1.5 times the shear modulus of the first material and/or the modulus of elasticity of the second material is at least 1.5 times the modulus of elasticity of the first material.

As a result, a one-piece plug connector can advantageously be provided which is easy to manufacture and at the same time has a significantly higher mechanical load capacity in the spring outer part or contact outer part than in the contact inner part. Due to the spring outer part, which supports the mechanical resilience of the contact inner part, the advantages of the one-piece connector can be combined with those of the two-piece connector. For example, a very inexpensive material can be used for the first material, which does not have to be a special alloy. At the same time, a simpler design and thus more cost-effective stamping and bending tool can be used, since no separate overspring has to be produced and then slipped over the contact box. If the overspring is manufactured in conventional designs in a second stamping and bending tool, this second stamping and bending tool can be dispensed with, as can a tool that pulls the outer spring part or outer contact part over the inner contact part.

For example, it can advantageously be provided that the inner contact part has a very high electrical conductivity. Provision can be made, for example, for the electrical conductivity of the first material to be at least 3 times the electrical conductivity of the second material, preferably at least 4 times.

The expression that the inner contact part is predominantly made of the first material is to be understood as meaning that the inner contact part is made of more than 50% of the first material, for example at least 70%, preferably more than 85% and particularly preferably more than 95%. Deviations from a complete design with the first material can result, for example, from the manufacturing process due to the stamping and bending process, or they can result from a possible surface coating of the first material, which is applied, for example, to reduce friction or to protect against corrosion. Such a surface coating can be present before the stamping and bending process, for example, but it can also be applied to the finished connector later. In the same way, the above consideration applies to the expression according to which the outer spring part or outer contact part is predominantly formed from the second material, i.e. more than 50%, for example at least 70%, preferably more than 85% and particularly preferably more than 95%.

Provision can also be made, for example, for the outer spring part or outer contact part to be located radially outside of the inner contact part for the majority of its area, i.e. more than 50%, e.g. at least 70% or at least 90%. Provision can be made for the outer spring part to be located completely radially outside of the inner contact part or for the outer spring part or outer contact part to be arranged completely outside of the inner contact part.

The two materials (first material and second material) can have the same thickness. However, it can also be provided that they have different thicknesses.

For example, the first material can have a first thickness and the second material can have a second thickness. It can be provided, for example, that the first thickness and the second thickness are less than 0.5 mm. For example, the first thickness and/or the second thickness can be in a range from 0.2 mm to 0.3 mm and can be 0.2 mm or 0.25 mm or 0.3 mm, for example. In other configurations, the second thickness can be in a range from 0.05 mm to 0.3 mm and can be, for example, 0.05 mm or 0.1 mm or 0.15 mm or 0.2 mm. It goes without saying that the first thickness can also have the stated thicknesses or material thicknesses. Provision can preferably be made for the second thickness to be less than the first thickness. For example, the first thickness can be at least 1.2 times the second thickness. As a result, the mechanically more stable second material can be made thinner, which reduces costs and weight, and it can still offer sufficient stabilization.

The inner contact part can be designed as a contact box, for example. The outer spring part or outer contact part can be designed as a spring box, for example. The inner contact part and/or the outer spring part can have, for example, a rectangular or round or triangular or oval cross section.

The manufacture of such a connector can be carried out, for example, by feeding a single sheet or metal strip into a stamping-bending tool, the sheet or metal strip having two areas of two different materials, the first material and the second material, which are inseparable (cannot be separated non-destructively) are connected to one another, e.g. by a casting process, a welding process, an embossing process, a bonding process or the like. In principle, it is also possible for two sheets of two different materials (first material and second material) to be inseparably connected to form a single sheet or metal band immediately before the stamping and bending process from two sheets or metal bands, e.g. by a welding process , and immediately afterwards the stamping and bending process for the production of the connector is carried out. In such a case, it can be provided that the process step of joining the metal sheet or the metal strip from two metal sheets or two metal strips is carried out in the same tool in which the punching-bending process is also carried out. However, it can also be provided that there are two separate tools (e.g. a joining tool and a stamping-bending tool).

It can be provided, for example, that after the provision of the single metal sheet, the inner contact part and the outer spring part or outer contact part are cut or punched in one step or in a sequence of steps from the metal sheet or metal strip (after the punching process there is a so-called stamped blank ). In a further step or at the same time as the stamping step, for example, individual elements can already be plastically deformed, e.g. in order to generate an elastically reversible spring preload on individual elements, which acts in the finished connector, e.g. along the radial direction or around predefined embossing points to be inserted into the stamping board. Furthermore, it can be provided, for example, that in a further step the punched-out outer spring part or outer contact part is folded over, e.g. on a fold line transverse to the axial direction by approximately 180°, so that it comes to lie adjacent to the punched shape of the inner contact part. Furthermore, it can be provided, for example, that in a further step the outer spring part is deformed into a box at buckling lines that run approximately or exactly parallel to the axial direction. In this way, in this sequence of steps, which is merely exemplary, the inner contact part is surrounded by the outer spring part or outer contact part, which is formed predominantly from the stronger second material. It can be provided, for example, that in the step of deforming the spring outer part or contact outer part to form a box, the contact inner part is also deformed. It can also take on a box shape, for example.

It goes without saying that the sequence of steps described above is merely exemplary and that individual steps can also be interchangeable or can be omitted. Further steps can also be provided.

In the context of this application, the expression “comprising” is used synonymously with the expression “comprising”, unless otherwise stated.

The fact that the plug connector is designed as a socket contact has the advantageous effect that the plug connector can be produced particularly easily as a stamped and bent part. Furthermore, this advantageously brings about a particularly secure and reliable contacting of a counter-contact element. This also has the advantageous effect that the connector only makes contact with mating contact elements of a defined shape.

In a further development it is provided that the plug connector has a connection area for fastening an electrical line, the connection area adjoining the inner contact part, the connection area being predominantly made of the first material, the connection area together with the inner contact part and the outer spring part or con clock outer part is formed from the single sheet metal as a stamped and bent part. This has the advantageous effect that the connector is designed to be particularly compact. Furthermore, the plug connector can advantageously be manufactured in a particularly simple and cost-effective manner in this way.

It goes without saying that the expression according to which the connection area is predominantly formed from the first material means that it is formed from more than 50% of the first material, preferably more than 70%, preferably more than 85% and particularly preferably more than 95%. The considerations made above regarding production-related proportions of the second material and/or regarding surface coatings also apply analogously to the connection area.

The connection area can be designed, for example, with a crimping lug or a pair of crimping lugs or two crimping lugs or two pairs of crimping lugs (insulation crimp and line crimp). It is also conceivable that the connection area has bonding pads for bonding wires of the line or for bonding the line, or that it has a welding surface for welding on the line. An embodiment of the connection area as an insulation displacement connection is also conceivable.

In a further development it is provided that the outer spring part or outer contact part is partially formed from the first material. For example, the outer spring part can be formed from the first material in a bending region in which the outer spring part is connected to the inner contact part, while viewed overall it predominantly comprises the second material. As a result, the bending process can advantageously be carried out in a particularly simple manner and the service life of the bending tool can be increased. This is because the first material is easier to form due to its material properties (shear modulus and/or modulus of elasticity). Another advantage is that the quality of the connector and the yield of connectors can be increased because, for example, damage to the abutting edge between the two materials is avoided. A bending area can be considered to be an area that extends, for example, up to 0.1 mm or up to 0.2 mm or up to 0.5 mm around a bending point of the sheet metal or the metal strip. Depending on the embodiment, however, it can also be provided that the bending area extends by up to 1 mm or by up to 2 mm or by up to 3 mm around a bending point of the sheet metal or the metal strip.

As an alternative or in addition, it can be provided that the inner contact part is partially formed from the second material. For example, the inner contact part can be formed from the second material in a (further) bending region in which the outer spring part is connected to the inner contact part, while viewed overall it predominantly comprises the first material. As a result, advantageously only, for example, an end face of the inner contact part facing the mating contact element can be designed to be more robust, for example to be more resistant to mismating attempts by the mating contact element. A mechanical reinforcement on a side surface of the inner contact part parallel to the axial direction can also be advantageously implemented in this way.

In a further development it is provided that the inner contact part has a contact lamella, the contact lamella being formed predominantly from the first material. This advantageously brings about a particularly reliable mechanical contacting of the mating contact element in the plugged-in state. The contact lamella can preferably be elastically and reversibly deflected. It can, for example, be resiliently prestressed in the radial direction with respect to a mating contact element to be inserted, so that it applies a defined normal force in the radial direction to the mating contact element in the inserted state. As a result, the plug connector can advantageously also be designed to be particularly robust against contact interruptions in the event of vibration loads.

It goes without saying that the connector or the inner contact part can have exactly one contact lamella. However, a plurality of contact lamellae can also be provided, e.g. two, three, four, five, six or even more contact lamellae.

The first material can preferably have high electrical conductivity, so that the electrical resistance of the current path from the mating contact element via the contact lamella to the connector and from there on to a line attached to the connector, for example, is particularly low.

Because the contact lamella has an embossed contact point, a defined contact point on the mating contact element is advantageously brought about in the inserted state. A further advantageous effect of this is a particularly low transition resistance to the mating contact element that is inserted.

In a further development it is provided that the inner contact part is supported mechanically on an inner side of the outer spring part or outer contact part. It can be provided, for example, that in particular one or more contact lamella(s) provided on the inner contact part the inside of the spring outer part supports or supports. Provision can furthermore be made, for example, for the inner contact part or the contact lamella(s) to be supported or supported along at least 25% of a length of the inner contact part or the contact lamella(s) along the axial direction on the inside of the spring outer part.

This has the advantageous effect that the inner contact part, which because of the first material has only a low stiffness (relative to the second material) or a low modulus of elasticity and/or shear modulus, is mechanically supported by the second material. This enables a permanently safe - and e.g. low-impedance - contacting of an inserted mating contact element. A sufficiently long support (e.g. along at least 25% of the length) makes it particularly easy to ensure, for example, that the mechanical support provided by the outer spring part or outer contact part does not only act selectively and for a limited time.

In a development, it is provided that the outer spring part or the outer contact part is designed to be closed all the way around, viewed along a direction of rotation that runs around the axial direction. This has the advantageous effect that the plug connector is not damaged, e.g. when it is plugged into a contact chamber of a plug housing, even when plugging in with higher forces. This can be of great importance, e.g. in the case of miniaturized connectors that have sheet metal thicknesses of less than 0.5mm or even less than 0.4mm or even less than or equal to 0.25mm. In this way, the inner contact part is also advantageously enclosed in the manner of a cage or box-like, so that forces acting radially outward in the inner contact part can always be supported on the outer spring part, which increases the stability of the connector.

In a further development it is provided that the outer spring part or the outer contact part has a locking lance which protrudes outwards and which can be elastically and reversibly displaced inwards, the locking lance being formed at least predominantly from the second material. This advantageously enables a particularly high primary holding force when the connector is pushed into a contact chamber of a connector housing, for example. The latching lance can, for example, protrude obliquely (radially) outwards from the outer part of the spring.

The latching lance can also be referred to as a primary latching lance or primary locking element. It can be designed to latch onto an undercut of a contact cavity of a connector housing when the connector is plugged in, so that it is not possible to pull the connector out of the contact cavity (without damage) without an unlocking tool. For permanent locking of the connector, a separate secondary locking element can be provided, which is e.g. pushed into the connector housing or its contact chamber and engages behind an undercut of the connector so that it cannot be pulled out of the contact chamber.

It goes without saying that the connector can have exactly one locking lance, but that it can also have several (e.g. two, three, four or even more) locking lances. In such a case, it is advantageously provided that each of these latching lances is formed at least for the most part from the second material.

A development provides that the first material is selected from the group: copper, a copper alloy, aluminum, an aluminum alloy. This advantageously provides a particularly high electrical conductivity of the connector. Furthermore, a low electrical resistance is advantageously provided between the plug connector and the mating contact element, since the mating contact element makes electrical contact with the inner contact part. Furthermore, the electrical resistance on the path or current path to a line connected to the plug connector is also advantageously kept low. A contact resistance of the plug connector to the electrical line that can be connected to the plug connector is also advantageously kept low in this way. Finally, this advantageously simplifies the stamping process and the bending process, since the proposed materials for the first material can be plastically deformed easily and with little effort. Finally, the use of expensive high-performance alloys can advantageously be dispensed with, which, despite high electrical conductivity, have a higher strength (modulus of elasticity and/or shear modulus) than, for example, pure copper or inexpensive copper alloys.

Alternatively or additionally, it can be provided that the second material is selected from the group: steel, spring steel. This advantageously brings about a particularly cost-effective manufacture of the connector. This is because steel or spring steel, as an easily deformable metallic material, has a high shear modulus and a high modulus of elasticity and can be obtained at low cost. As a spring outer part or contact outer part, the second material proposed in this way can also be used in the connector with very small dimensions, for example material thicknesses of approximately 0.5 mm or approximately 0.4 mm or approximately 0.3 mm or approximately 0.2 mm or approximately 0.15 mm or of about 0.1mm mechanically stabilize in such a way that high primary holding forces (e.g. by means of a locking lance or by means of an undercut behind which a locking lance of a contact chamber of a connector housing engages) are achieved against being pulled out of a contact chamber of a connector housing and at the same time a high contact normal force of the inner contact part or a contact lamella arranged therein can be effected relative to an inserted mating contact element.

character list

Further features and advantages of the present invention will become apparent to those skilled in the art from the following description of exemplary embodiments, which, however, are not to be construed as limiting the invention, with reference to the accompanying drawings.

• 1: eine schematische Darstellung einer Stanzplatine mit Biegelinien zur Herstellung einer Ausführungsform eines Steckverbinders;
• 2a: einen schematischen Längsschnitt durch einen Steckverbinder, der aus der Stanzplatine aus 1 hergestellt ist;
• 2b: einen schematischen Querschnitt durch einen Steckverbinder, der aus der Stanzplatine aus 1 hergestellt ist;
• 2c: eine schematische perspektivische Teilansicht des Steckverbinders aus den 2a und 2b.

Show it

• 1 1: a schematic representation of a stamped blank with bending lines for producing an embodiment of a plug connector;
• 2a : a schematic longitudinal section through a connector that is made out of the stamped board 1 is manufactured;
• 2 B : a schematic cross-section through a connector emerging from the stamped board 1 is manufactured;
• 2c : a schematic perspective partial view of the connector from the 2a and 2 B .

1 shows an example of a schematic representation of a stamped board 70 with bending lines 50, 52 for the production of an embodiment of a connector 1 (see 2a , 2 B , 2c ). After its production, this is designed as a socket contact by means of various bending steps.

The individual components of the plug connector 1 have already been punched out on the punched board 70 shown and some of them have already been pre-bent or stamped out.

The connector 1 (see different views in 2a , 2 B , 2c ) has a contact inner part 2 extending along an axial direction A for receiving a mating contact element 20 . It also has an outer spring part 3, which can also be referred to as the outer contact part. The outer spring part 3 (or outer contact part) is arranged outside of the inner contact part 2 with respect to a radial direction R, which extends transversely to the axial direction A, with the inner contact part 2 being predominantly made of a first material M1, with the outer spring part 3 being predominantly made of a second Material M2 is formed, wherein the shear modulus of the second material M2 is at least 1.5 times the shear modulus of the first material M1 and wherein in this exemplary embodiment the modulus of elasticity of the second material M2 is at least 1.5 times the modulus of elasticity of the first material M1 is. In this exemplary embodiment, the first material M1 is copper or an inexpensive copper alloy and the second material M2 is steel. The inner contact part 2 and the outer spring part 3 are formed from a single metal sheet 5 as a stamped and bent part, with the first material M1 having a first thickness d1 and the second material M2 having a second thickness d2.

In this exemplary embodiment, the outer spring part 3 (or the outer contact part) is closed in the form of a box with a rectangular cross section. The outer spring part 3 has here, for example, a bottom 32 of the outer spring part (or a bottom of the outer contact part), two side walls 33 of the outer spring part and a cover 34 of the outer spring part. The outer spring part 3 is in the finished state (see e.g 2 B , 2c ) formed circumferentially closed, viewed along a circumferential direction U, which encircles the axial direction A.

It goes without saying that other cross-sections of the outer spring part 3 are also possible and shapes are also possible in which the outer spring part 3 is largely open, i.e. not closed all the way around (e.g. with perforated outer spring part -side walls 33 and/or perforated outer spring part- Floor 32 and/or perforated outer spring part cover 34).

The contact inner part 2 has a contact inner part base 22 which acts as a kind of contact lamella 8 in that an inserted mating contact element 20 comes into mechanical and electrical contact with the contact inner part base 22 . The inner contact part 2 also has two side webs 23, which are designed in the manner of a side wall of the inner contact part that is shortened along the axial direction A, and a cantilevered contact blade 8—in this exemplary embodiment—which is connected to one of the side webs 23 and has a free end which faces the mating contact element 20 in the completed state of the plug connector 1 . A contact point 9 is embossed in each of the contact lamella 8 and in the contact inner part base 22, with the two contact points 9 facing each other when the connector 1 is assembled and contacting an inserted mating contact element 20 mechanically and electrically at a defined point. Contact inner part floor 22 and the contact blade 8, the corresponds to a contact inner part cover are formed here for the most part from the first material M1.

In the finished connector (see e.g 2 B) the contact inner part 2 and here in particular the contact lamella 8 is supported mechanically on an inner side 31 of the spring outer part 3 . This support takes place, for example, over at least 25% of a length L of the inner contact part 2 along the axial direction A. In this way, the outer spring part 3 with its mechanically more stable second material M2 can meet the mechanical requirements of the elements of the Contact inner part 2 support.

In the present exemplary embodiment, relatively inexpensive copper can thus be used as the first material M1. This ensures very good electrical conductivity. Since the mechanical strength is provided by the spring outer part 3, an expensive high-performance copper alloy can be dispensed with.

In the present exemplary embodiment, the plug connector 1 also has a connection area 4 for fastening an electrical line 6, merely by way of example, the connection area 4 adjoining the inner contact part 2, the connection area 4 being predominantly formed from the first material M1, the connection area 4 together is formed with the contact inner part 2 and the spring outer part 3 from the single sheet metal 5 as a stamped and bent part.

The electrical line 6 has insulation 61 here, for example, which encloses an electrical conductor 62 . In this exemplary embodiment, the electrical line 6 can be electrically and mechanically contacted or connected to the connector 1 in the connection area 4 by means of insulation crimping tabs 42 and line crimping tabs 41 or can be attached to the connector 1 . It goes without saying that other options for electrical and mechanical contacting are also possible, e.g. by bonding, soldering, welding, insulation displacement connection, etc. It is also not absolutely necessary for a connection area 4 to be provided.

In this embodiment, the connector 1 is designed as a lance contact. For this purpose, it is provided that the outer spring part 3 (or the outer contact part) has a (here: obliquely) outwardly protruding locking lance 10 which can be elastically and reversibly displaced inwards, the locking lance 10 being formed from the second material M2. The latching lance is formed here, for example, on the spring outer part cover 34 or is punched out of it. It goes without saying that more than one locking lance 10 can also be provided, e.g. another locking lance 10 which is punched out of the bottom 32 of the outer spring part. By means of the latching lance 10, the plug connector 1 can be primarily latched, e.g. By forming the latching lance 10 from the second material M2, higher primary holding forces or pull-out forces can be achieved with otherwise the same dimensions than would be possible with the configuration from the first material M1.

In other embodiments, the locking lance 10 can be dispensed with. In other embodiments, for example, a recess can be provided in the spring outer part 3, into which a spring element of a contact chamber can engage and thus latch the connector in a contact chamber of a connector housing, in particular primary latching (instead of a recess, only an undercut can also be provided). In such an embodiment, too, it is advantageous that the recess (or the undercut) is provided in (or on) the outer spring part 3 or outer contact part and is in particular formed from the second material M2, since this material has otherwise the same dimensions offers better mechanical stability than the first material M1.

In 1 it can be seen how the plug connector 1 can be produced after the sheet metal 5 has been provided in a first step and in a further step the above-described elements of the plug connector 1 have already been punched out of the sheet metal 5, as well as the contact lamella 8 in their resilient form was brought and the contact points 9 were stamped into the sheet. In 1 the stamped blank 70 is still essentially in the two-dimensional shape of the metal sheet. The sheet metal 5 or the metal strip of the stamped blank 70 has two areas made of two different materials, the first material M1 and the second material M2, which are inseparable (not non-destructively separable) connected to one another, e.g. by a casting process or a welding process or an embossing process or a gluing process or the like.

In a further step 200, the stamped-out spring outer part 3 is folded over in this exemplary embodiment, here at the fold line 50, which runs transversely to the axial direction A and lies approximately at the abutting edge between the two materials M1, M2.

The bending occurs here by approximately 180°, so that the stamping die of the spring outer part 3 (or of the contact outer part 3) comes to lie adjacent to the stamping die of the contact inner part 2. In a further exemplary step, the outer spring part 3 is deformed into a box at buckling lines 52 that run approximately or exactly parallel to the axial direction A, with the bending taking place in such a way that the inner contact part 2 comes to rest radially inside the outer spring part 3. In this way, in this sequence of steps, which is merely exemplary, the inner contact part 2 is surrounded by the outer spring part 3, which is formed predominantly from the stronger second material M2. The latching lance 10 can already be removed from the stamped blank before step 200 of the first bending.

It goes without saying that other stamping patterns and/or bending sequences are also possible, e.g. the inner contact part 2 can be bent first, then the outer spring part 3 can be bent and in a further step, the inner contact part 2, which has already been folded or bent, can be bent around.

It is also understood that the choice of material described above as an example is not an essential feature of the invention; other material pairings are also possible in principle, as long as the second material M2 has a modulus of elasticity that is at least 1.5 times that of the first material M1 and/or as long as the second material M2 has a shear modulus at least 1.5 times that of the first material M1. Provision can be made, for example, for the first material M1 to be selected from the following group: copper, a copper alloy, aluminum, an aluminum alloy, silver, a silver alloy, gold, a gold alloy. Alternatively or additionally, it can be provided that the second material M2 is selected, for example, from the group: steel, spring steel, iron.

Provision can also be made for at least one coding tag and/or at least one insertion bevel (e.g. at the front end facing counter-contact element 20) to be provided on connector 1. Such elements are preferably formed from the second material M2, since this is mechanically more stable.

Provision can be made for the outer spring part 3 to be formed in part from the first material M1. This can occur, for example, in a bending area 7 in which the outer spring part 3 is connected to the inner contact part 2 . Such a bending area 7 can, for example, be in a range of up to 3 mm, preferably at most up to 2 mm and very particularly preferably at most up to 1 mm and further preferably by at most up to 0.5 mm, e.g. 0.1 mm or 0.2 mm or 0. 3mm or 0.5mm around the abutting edge between the two materials M1, M2.

Alternatively or additionally, it can be provided that the inner contact part 2 is partially formed from the second material M2, in particular in the bending region 7 in which the outer spring part 3 is connected to the inner contact part 2 . As a result, for example, a front end of the connector 1 that is robust against incorrect insertion of the connector 1 into the contact chamber and/or against incorrect insertion of the mating contact element 20 can be formed.

In the present exemplary embodiment, for reasons of better clarity, a connector 1 is shown in which the bending has taken place along the bending line 50 or buckling line 50 at the abutting edge between the two materials M1, M2.

It can also be provided that the first thickness d1 of the first material M1 differs from the second thickness d2 of the second material M2. In this case, for example, the first thickness d1 of the first material M1 for the inner contact part 2 can be made smaller than the second thickness d2 of the second material M2. As a result, costs for the generally more expensive first material M1 can advantageously be saved, since the inner contact part 2 is mechanically stabilized by the outer spring part 3 (or outer contact part). In the present exemplary embodiment, the first thickness d1 and the second thickness d2 are of the same size, also for reasons of clarity, which, however, also makes technically particularly simple handling possible, e.g. when guiding the metal sheet 6.

Claims (10)

Connector, the connector comprising: -- an inner contact part (2) extending along an axial direction (A) for receiving a mating contact element (20), -- an outer spring part (3), the outer spring part (3) outside the inner contact part (2) is arranged transversely to the axial direction (A) with respect to a radial direction (R), the inner contact part (2) being predominantly formed from a first material (M1), the outer spring part (3) being predominantly formed from a second material (M2). , wherein the inner contact part (2) and the outer spring part (3) are formed from a single metal sheet (5) as a stamped and bent part, the shear modulus of the second material (M2) being at least 1.5 times the shear modulus of the first material (M1) is and/or wherein the modulus of elasticity of the second material (M2) is at least 1.5 times the modulus of elasticity of the first material (M1),. connector after claim 1 , wherein the connector (1) is designed as a socket contact. Connector according to one of the preceding claims, wherein the connector (1) has a connection area (4) for attaching an electrical line (6), the connection area (4) adjoins the inner contact part (2), the connection area (4) being predominantly formed from the first material (M1), the connection area (4) together with the inner contact part (2) and the outer spring part (3 ) is formed from the single sheet (5) as a stamped and bent part. Connector according to one of the preceding claims, the outer spring part (3) being partially formed from the first material (M1), in particular in a bending region (7) in which the outer spring part (3) is connected to the inner contact part (2). and or wherein the inner contact part (2) is partially formed from the second material (M2), in particular in a bending area (7) in which the spring outer part (3) is connected to the contact inner part (2). Connector according to one of the preceding claims, wherein the inner contact part (2) has a contact lamella (8), the contact lamella (8) being formed predominantly from the first material (M1). Connector according to the preceding claim, wherein the contact blade (M1) has an embossed contact point (9). Connector according to one of the preceding claims, wherein the inner contact part (2), in particular the contact lamella (8), is mechanically supported on an inner side (31) of the outer spring part (3), in particular over at least 25% of a length (L) of the inner contact part (2 ) along the axial direction (A). Plug connector according to one of the preceding claims, in which the outer spring part (3) is designed to be closed all the way around, viewed along a direction of rotation (U) which runs around the axial direction (A). Connector according to one of the preceding claims, the outer spring part (3) having a locking lance (10) which protrudes outwards and can be elastically and reversibly displaced inwards, wherein the locking lance (10) is formed from the second material (M2). Connector according to one of the preceding claims, wherein the first material (M1) is selected from the group: copper, a copper alloy, aluminum, an aluminum alloy and/or the second material (M2) being selected from the group: steel, spring steel.

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