This application claims priority to German Patent Application No. 10 2022 104 701.6, filed on Feb. 28, 2022; which is incorporated in its entirety herein.
The present invention relates to an electrical contact element having a frame clamp for connecting at least two electrical conductors with the features of the preamble of claim 1.
Electrical contact elements are used, for example, in vehicle technology for contacting at least two electrical conductors of an electric drive or a battery cell or energy cell. In this case, the electrical contact elements themselves serve to produce the electrical contacts between the electrical conductors by fixing the electrical conductors in the contact position and applying the clamping forces required for the connection. For this purpose, the electrical contact elements of the generic type have a frame clamp, which itself has a frame with a stationary thread, a clamping shoe and a clamping screw engaging in the stationary thread and supported on the clamping shoe for clamping the electrical contacts. The clamping screw serves to apply the required clamping forces via the clamping shoe, while the frame of the frame clamp serves as an abutment and receptacle for the electrical conductors. The frame itself is formed by a metal strip bent repeatedly, which, in addition to its function of forming the abutment, additionally serves to hold the thread in a stationary manner, into which the clamping screw engages and is supported during the screwing movement. The frame thus also forms the abutment necessary for applying the required clamping forces for the clamping screw.
The invention is based on the object of providing an electrical contact element having a frame clamp, which is to be handled as easily as possible for implementing the electrical contact.
In order to achieve the object, it is proposed according to the basic idea of the invention that a plastic holder having a cavity having two insertion openings arranged on opposite walls of the cavity is provided for inserting two electrical conductors to be contacted with one another, in which cavity the frame clamp is arranged, and the frame clamp is captively fixed in the cavity of the plastic holder by means of a latching, and the frame clamp is mounted in the cavity of the plastic holder in a floating manner in the direction of at least one axis, which is oriented orthogonally to an insertion direction of the electrical conductors into the insertion openings.
According to the solution according to the invention, it is thus proposed to provide a plastic holder with a cavity in which the frame clamp is arranged. The plastic holder serves to insulate the frame clamp from the outside and in particular to the vehicle structure and, if present, in addition to adjacent frame clamps. In addition, the plastic holder serves to protect the frame clamp and the electrical contact point from the outside. Furthermore, the electrical contact element can be handled in a simplified manner by the plastic holder during the assembly process by the plastic holder comprising a specific shape for handling in an automated assembly process, for example. Furthermore, a direct contact of the frame clamp during the handling of the electrical contact element can be avoided by the handling of the electrical contact element via the plastic holder. So that the electrical conductors can be contacted as intended by means of the frame clamp arranged in the plastic holder, the cavity of the plastic holder has an insertion opening on two opposite walls, through which the electrical conductors can be inserted. So that the electrical contact element can be handled in a simplified manner during transport and during assembly, the frame clamp is also held captively in the plastic holder by a latching that is easy to realize. It is further proposed that the frame clamp is mounted in a floating manner in the cavity of the plastic holder in the direction of at least one axis, which is oriented orthogonally to an insertion direction of the electrical conductors into the insertion openings. The floating mounting enables the electrical conductors to be contacted with a certain height tolerance of the conductors. The frame clamp can, practically within the play created by the floating mounting, automatically align itself with the electrical conductors in the case of a stationary plastic holder. In this case, the floating mounting can be realized very easily in conjunction with the latching, in that the latching and the latching position of the frame clamp defined thereby is designed such that the frame clamp is arranged in the latching position with a corresponding play to form an abutment of the plastic holder and can thereby carry out slight movements in relation to the latter.
It is further proposed that the frame has at least one recess, and the plastic holder has at least one first latching lug arranged on an inner side of a wall of the cavity, and the latching is formed by an engagement of the first latching lug in the recess. As a result of the recess on the frame and the first latching lug protruding into the cavity, the frame clamp automatically latches with its frame into the cavity relative to the plastic holder during the insertion movement.
It is further proposed that the engagement of the first latching lug in the recess in this case limits the floating mounting in one direction of the axis. In addition to its latching function, the first latching lug thus forms one of the stops of the floating mounting of the frame clamp in a direction of the axis relative to the plastic holder.
It is further proposed that the plastic holder comprises an insertion opening for the frame clamp, and the first latching lug has a shape which tapers in the direction of the insertion movement of the frame clamp conically towards the center of the plastic holder on its side facing the insertion opening. As a result of the proposed embodiment of the latching lug, the latter is displaced continuously toward the outer side during the insertion movement with an increasing deflection, such that the latching process can be realized as gently as possible with as little load as possible on the latching lug, the plastic holder and finally the frame clamp.
It is further proposed that the plastic holder has at least one second latching lug, which is positioned such that it blocks a movement of the clamping shoe in the direction of an abutment arranged on the frame up to a predetermined pressure force of the clamping shoe. The two electrical contacts are inserted into the frame clamp into a free space between the clamping shoe and a base surface of the frame for the production of the electrical contact and then clamped by screwing the clamping screw between the clamping surface of the clamping shoe and the base surface of the frame. So that the electrical contacts can be reliably inserted into the free space, the clamping shoe is held by the second latching lug at a defined minimum distance from the base surface of the frame, such that the free space between the base surface of the frame and the clamping surface of the clamping shoe has a sufficient opening width for inserting the electrical conductors. In this case, the second latching lug is dimensioned such that, when the clamping screw is screwed and a feeding movement of the clamping shoe which is thereby forced after a predetermined compressive force is exceeded, the second latching lug automatically deforms towards the side and subsequently no longer prevents the further clamping movement of the clamping shoe. Furthermore, prior to screwing, the second latching lug prevents an uncontrolled movement in the direction of the clamping surface of the frame and thereby forms an additional securing of the clamping shoe against unintentional slipping out of the plastic holder.
In this case, the second latching lug can preferably have a shape which tapers in the direction of the clamping movement of the clamping shoe conically towards the center of the plastic holder on its side facing the clamping shoe. As a result, the rise in the compressive force required to overcome the second latching lug can be formed to be continuously increasing.
In this case, the second latching lug is designed such that the predetermined pressure force, up to which the movement of the clamping shoe is blocked, is smaller than the counterforce exerted by the first latching lug on the frame. The first and second latching lugs are identical in their latching direction, wherein the first latching lug is already latched after the assembly, i.e. the return movement of the frame from the cavity of the plastic holder is blocked in a latching position, while the second latching lug is not yet latched.
The compressive force exerted on the clamping shoe is brought about by a screw connection of the clamping screw in the thread of the frame, such that the feeding movement of the clamping shoe results in an oppositely directed tensile force exerted on the frame via the thread. This tensile force is supported on the plastic holder via the first latching lug. So that the frame clamp executes the feeding movement into the frame during the screwing together with the clamping shoe and is not instead pulled out of the plastic holder with the frame, overcoming the first latching lug, the reaction force exerted by the first latching lug can be greater than the compressive force of the clamping shoe that is to be overcome during the feeding movement of the clamping shoe and defined by the second latching lug. These force conditions can be realized very easily by the shape of the two latching lugs and the corresponding counter surfaces on the clamping shoe and the frame.
It is further proposed that the first latching lug and the second latching lug are arranged on inner side faces of the walls of the cavity of the plastic holder, which side faces are arranged at right angles to one another. Due to the proposed arrangement of the two latching lugs, the plastic holder can be produced particularly easily in an injection-molding process. Furthermore, the plastic holder is thus loaded more uniformly, and the latching processes can be carried out more easily without a mutual interference. A further advantage of this solution is that, in the event of a deformation of the walls with the second latching lugs towards the outside during the overcoming of the second latching lugs, this deformation does not have a disadvantageous influence on the latching of the first latching lugs, since the first and the second latching lugs are arranged on different walls.
It is further proposed that in each case two pairs of first and/or second latching lugs are provided, which are each arranged in pairs on opposite walls of the cavity of the plastic holder. The latching function realized by the first and the second latching lugs can thus be improved by the opposite arrangement of two latching lugs in each case by means of the opposite arrangement of two first latching lugs or two second latching lugs, since this enables latching of the frame clamp or a play-free mounting of the clamping shoe to two opposite walls, thus a latching with increased stability with respect to the plastic holder.
It is further proposed that the plastic holder comprises guide ribs on the inner side surfaces of the walls, which run parallel to the direction of the insertion movement of the frame clamp. As a result of the guide ribs, the movement of the frame clamp overall can be improved by a guide as such and in particular in a direction predetermined by the guide ribs.
It is further proposed that at least one further frame clamp is provided in the plastic holder, which frame clamp is mounted insulated by the plastic holder. The proposed development makes it possible to use the electrical contact element for contacting further electrical lines, which are thus insulated from one another independently of one another.
The invention is explained below using preferred embodiments with reference to accompanying figures. In the drawings:
The plastic holder 3 of the electrical contact element 1 can be seen as an individual part in
The clamping screw 21 is designed as a hexagonal socket screw and engages with its thread into the thread 25 of the frame 20. The thread 25 is formed by the shaping with the annular extension 24 in the one end 27 of the strip in an integral component of the frame 20 and thus in a stationary manner. However, it would also be conceivable to use a threaded insert, which is produced as a separate part and is held stationary relative to the frame 20. In this case, stationary is to be understood in the sense of the invention in that the clamping screw 21 can be supported on the thread 25 during the screwing movement and is forced to the feeding movement explained in more detail below.
The clamping screw 21 projects with its free end into the frame 20 and is provided at its free end with a clamping shoe 22. Furthermore, the frame 20 comprises in each case a recess 9 on its upright side walls, which side walls are positioned in such a way that the frame clamp 2 automatically latches into the recesses 9 by engagement of two oppositely arranged first latching lugs 10 of the plastic holder 3 when inserted into the insertion opening of the cavity 8 and is thereby held captively in the plastic holder 3. The first latching lugs 10 are arranged on the inner side surfaces of two opposite walls 17 of the plastic holder 3 and project into the cavity 8. Furthermore, the first latching lugs 10 are conically shaped in that the surfaces 7 of the first latching lugs 10 facing the insertion opening of the cavity 8 run obliquely to the center of the cavity 8 in the insertion direction of the frame clamp 2 and starting from the walls 17. The surfaces of the first latching lugs 10 facing away from the insertion opening are oriented perpendicular to the inner side surfaces of the walls 17 and thus perpendicular to the insertion direction of the frame clamp 2, such that the first latching lugs 10 come to rest in the latched position with their vertical surfaces on the edges of the recesses 9 and block a retraction movement of the frame clamp 2. In the latched position, the frame clamp 2 is then captively held in the cavity 8 of the plastic holder 3. Alternatively, the first latching lugs 10 can also be formed by an upper, inwardly projecting edge portion which, after being inserted, comprises the upper side of the frame clamp 2 and thereby blocks the retraction movement of the frame clamp 2, as a result of which the recesses 9 for latching the frame clamp 2 can again be omitted.
The position of the first latching lugs 10 is selected in conjunction with the arrangement of the recesses 9, such that the frame clamp 2 is mounted in a floating manner in the plastic holder 3 via the first latching lugs 10 between the base plate 30 of the plastic holder 3 and the first latching lugs 10 in the direction of the insertion movement of the frame clamp 2 into the plastic holder 3.
The clamping shoe 22 comprises a clamping surface 23 on its side facing the base plate 32 of the frame 20. The base plate 32 of the frame 2 also comprises a clamping surface 29 on the surface facing the clamping shoe 22. The free space between the clamping surfaces 23 and 29 serves to introduce and clamp the electrical conductors 4 and 5, as will be described in more detail below.
Two second latching lugs 11 are arranged on the upper edge sides of the insertion openings 14 and 15, said second latching lugs 11 having a conical shape, similar to the first latching lugs 10, on the upper sides thereof facing the insertion opening of the plastic holder 3, having a shape extending from the walls 17 in the insertion direction of the frame clamp 2 into the cavity 8, extending towards the center of the cavity 8. The second latching lugs 11 are positioned in such a way that the clamping screw 21, with its clamping shoe 22 and the insertion bevels 13 formed thereon, rests against it before the electrical conductors 4 and 5 are installed and is held at a distance from the base plate 32. As a result, the free space between the clamping surfaces 23 of the clamping shoe 22 and the clamping surface 29 of the base plate 32 is kept open for a reliable insertion of the electrical conductors 4 and 5. Due to the contact of the clamping shoe 22 with its insertion bevels 13 on the conical surfaces of the second latching lugs 11, the clamping shoe rests as flat as possible against the second latching lugs 11, as can also be seen in the enlarged view of
For mounting or electrical contacting of the electrical conductors 4 and 5, these are first inserted into the free space between the clamping surfaces 23 and 29 through the insertion openings 14 and 15 of the plastic holder 3. In this case, certain height deviations of the electrical conductors 4 and 5 can be compensated by the floating mounting of the frame clamp 2. Furthermore, the insertion movement of the electrical conductors 4 and 5 is simplified and guided by the insertion bevels 12 and 13. After the insertion of the electrical conductors 4 and 5 into the position to be seen in
As can be seen in
Two first latching lugs 10 and two second latching lugs 11 are provided on the plastic holder 8 on the opposite walls 17, as a result of which the latching of the frame clamp 2 and of the clamping shoe 22 can be realized in a stable and tilt-proof manner. In particular, an unintentional release of the latching can thereby be prevented.
An electrical contact element (1) having a frame clamp (2) having
characterized in that
The electrical contact element (1) according to embodiment 1, characterized in that
The electrical contact element (1) according to embodiment 2, characterized in that
The electrical contact element (1) according to any of embodiments 2 to 3, characterized in that
The electrical contact element (1) according to any of the preceding embodiments, characterized in that
The electrical contact element (1) according to embodiment 5, characterized in that
The electrical contact element (1) according to any of embodiments 2 to 4 and according to any of embodiments 5 or 6, characterized in that
The electrical contact element (1) according to any of embodiments 2 to 4 and according to any of embodiments 5 or 6 or according to embodiment 7, characterized in that
The electrical contact element (1) according to any of embodiments 2 to 4 or according to any of embodiments 5 to 8, characterized in that
The electrical contact element (1) according to any of the preceding embodiments, characterized in that
The electrical contact element (1) according to any of the preceding embodiments, characterized in that
Number | Date | Country | Kind |
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10 2022 104 701.6 | Feb 2022 | DE | national |