CONTACT POINT FOR A FLAT CONDUCTOR

Abstract

A contact point for establishing a connection to a conductor element according to the present disclosure comprises a flat conductor having first and second ends, and a contact element connected to the flat conductor in a terminal area of the flat conductor, wherein the contact element is also configured to connect to the conductor element. The contact point comprises a multi-shell housing attached to the flat conductor and configured to cover the contact element and the terminal area. The housing comprises at least three openings, wherein first and second openings enable passage of first and second ends of the flat conductor, and a third opening enables passage of the conductor element. A gasket is attached to at least one of the openings for sealing the housing.

Claims

1. A contact point for establishing a connection to a conductor element, the contact point comprising: a flat conductor having first and second ends and a terminal area; a contact element connected to the flat conductor in the terminal area of the flat conductor, wherein the contact element is also configured to connect to the conductor element; a housing attached to the flat conductor and configured to cover the contact element and the terminal area, the housing comprising: a first opening enabling passage of the first end of the flat conductor; a second opening enabling passage of the second end of the flat conductor; and a third opening enabling passage of the conductor element; and a gasket attached to at least one of the openings for sealing the housing.

2. The contact point according to claim 1, wherein the flat conductor is enveloped in a layer of insulation.

3. The contact point according to claim 1, wherein the housing is a multi-shell housing comprising at least two interconnectable shells.

4. The contact point according to claim 3, wherein the shells at least partially overlap when interconnected.

5. The contact point according to claim 3, wherein the shells are interconnected by a latch connection.

6. The contact point according to claim 3, wherein the shells are interconnected by a plurality of latch connections on respective sides of at least one of the flat conductor or the contact element.

7. The contact point according to claim 1, comprising: a fuse connecting the contact element and the conductor element, wherein the housing is configured to cover the fuse.

8. The contact point according to claim 7, wherein the fuse is detachably connected to the contact element and the conductor element.

9. The contact point according to claim 8, wherein the fuse is detachably connected via screw connections.

10. The contact point according to claim 9, wherein the housing comprises female profiles on an inner side, the female profiles configured to align at least one of the fuse or the screw connections.

11. The contact point according to claim 10, wherein the gasket is produced with the housing in a two-component injection molding process.

12. The contact point according to claim 7, wherein the housing comprises a dehumidifying port in the area of the fuse.

13. The contact point according to claim 1, wherein the housing comprises a drip rim directed downwardly when installed.

14. A contact point for establishing an electrical connection to a conductor element, the contact point comprising: a flat conductor having first and second ends; a contact element connected to the flat conductor in a terminal area of the flat conductor; a fuse connecting the contact element and the conductor element; a multi-shell housing attached to the flat conductor and configured to cover the contact element, the terminal area, the fuse, and at least a portion of the conductor element, the housing comprising: a first opening enabling passage of the first end of the flat conductor at the terminal area; a second opening enabling passage of the second end of the flat conductor at the terminal area; and a third opening enabling passage of the conductor; and a gasket attached to at least one of the openings for sealing the multi-shell housing.

15. The contact point according to claim 14, wherein the housing comprises fiberglass-reinforced polyamide, and the gasket comprises thermoplastic elastomer (TPE) or ethylene propylene diene rubber (EPDM).

16. The contact point according to claim 14, wherein the housing comprises an upper shell and a lower shell, the shells at least partially overlapping when interconnected.

17. The contact point according to claim 16, wherein the gasket is attached to the third opening, the gasket comprising two U-shaped sealing rings configured to provide overlapping sealing zones.

18. The contact point according to claim 17, wherein a first of the two U-shaped sealing rings is attached to the upper shell and a second of the two U-shaped sealing rings is attached to the lower shell.

19. The contact point according to claim 16, wherein the shells are interconnected by a plurality of latch connections on respective sides of at least one of the flat conductor or the contact element.

20. The contact point according to claim 14, wherein the housing comprises a dehumidifying port in the area of the fuse.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0022] In the drawings:

[0023] FIG. 1 shows a plan view of an exemplary contact point with a closed housing;

[0024] FIG. 2 shows a plan view of an exemplary contact point with an open housing;

[0025] FIG. 3 shows a plan view of the lower shell of an exemplary housing;

[0026] FIG. 4 shows a side view of the upper shell of an exemplary housing; and

[0027] FIG. 5 shows an exemplary sealing element on the conductor.

DETAILED DESCRIPTION

[0028] FIG. 1 shows a contact point 1 according to the present disclosure after all individual parts have been mounted to create a fuse-protected single-conductor connection from a flat conductor 2. A section of a rectangular flat conductor 2 made of, for example, aluminum is shown in a terminal area 11. For example, one such flat conductor may measure 30×2 mm and be insulated with polypropylene (PP) or polyvinyl chloride (PVC) approximately 1 mm thick. This flat conductor 2 is to be connected to a conductor 4, such as a round stranded conductor of copper or aluminum with insulation of PP or PVC.

[0029] The connection is made inside a housing 5 comprising two interconnected shells 51, 52 that cover the contact point 1. The interconnected shells may comprise an upper shell 51 and a lower shell 52. As shown in FIG. 1, this housing 5 has three openings. Two openings 8, 9 enable passage of the flat conductor 2, and one opening 10 enables passage of the conductor 4. Female profiles 54 shown in the housing 5 accommodate a fuse 6 (shown in FIG. 2) on the inner side 53 of the housing 5, as explained in further detail below.

[0030] Additional details of the contact point 1 of the present disclosure are shown in FIG. 2. FIG. 2 shows housing 5 with an upper shell 51 removed. A lower shell 52 of the housing accommodates the flat conductor 2. Detent lugs 60, oriented toward the middle of the flat conductor 2, and an insertion guide with an inclination descending toward the middle of the flat conductor 2, are located on the walls of the lower shell 52 that correspond to the narrow sides of the flat conductor 2. This may enable the flat conductor 2 to be inserted and latched to the lower shell 52 before the upper shell 51 is attached.

[0031] A cladded contact element 3 is affixed to the flat conductor 2. The contact element may be made of copper or aluminum, for example. The contact element 3 is stamped from a roll-cladded blank with a copper/aluminum transition. After the stamping step, both the area to be affixed to a fuse 6 and the aluminum/copper transition are coated. The coating may be nickel and tin or tin and silver. The aluminum/copper transition may also be protected from electrochemical corrosion or electrolytes by varnishing, overmolding or other coating processes. The partially coated, cladded contact element 3 is welded with a laser at an uncoated aluminum side to a terminal part (that may be made of aluminum) of the flat conductor 2. This may yield an aluminum-to-aluminum connection with good conductive properties. The cladded, coated aluminum/copper transition is not damaged by the welding process.

[0032] The contact element 3 has an opening into which a screw may be inserted, such that a fuse 6 may be connected to the contact element 3 by a detachable screw connection 22. The terminal part and the contact element 3 are perpendicular to the narrow side of the flat conductor 2 and the fuse 6 is further turned by the screw connection 22 by 90° relative to the contact element 3. Accordingly, the fuse 6 is substantially parallel to the flat conductor 2. However, it is also contemplated to orient the fuse and the line exit perpendicular to the flat conductor 2.

[0033] The fuse 6 is connected to the conductor 4 on a side facing away from the contact element 3. The conductor 4 ends with a contact element that is crimped or welded to the conductor 4. This contact element has an opening that aligns with another opening of the fuse 6. Thus the fuse 6 and the contact element of the conductor 4 may be connected by an additional screw connection 21. The fuse 6 is thus detachably affixed to the conductor 4 and the contact element 3, thereby facilitating easier replacement of the fuse 6 after it has been triggered.

[0034] The lower shell 52 also serves as a support for the fuse 6, the screw connections 21, 22 and the contact element 3. The housing 5 covers the entire contact point 1 and is approximately L-shaped, or T-shaped if the fuse 6 is perpendicularly oriented. The housing 5 in total may therefore measure approximately 60×80 mm with a height of approximately 10 mm. The lower shell 52 has a plurality of latch connections 57, 58. As shown in FIG. 2, the lower shell may have two latches 57, 58 on both sides of the flat conductor and one or three latches 57, 58 on the respective sides of the fuse 6. The latches 57, 58 each consist of a bracket projecting from the lower shell 52 and pointing up from below toward the upper shell. A detent lug of the latches 57, 58 of the upper shell 51 engages in the center of the bracket, as shown in FIG. 4. This structure of the latches 57, 58, in which the upper shell 51 moves between the bracket and the side wall of the lower shell 52, prevents the penetration of moisture into the housing 5 caused by splashes or drops of water.

[0035] The housing 5 exhibits additional properties for sealing the contact point 1, as further explained below. FIG. 3 shows the lower shell 52 of the housing 5 without the inserted flat conductor 2, fuse 6 and conductor 4. Dehumidifying ports 56 are visible at the lowest points of the shell 52, between the screw connections 21, 22 and underneath the crimp for the conductor 4. Any penetrating moisture can escape through the dehumidifying ports 56.

[0036] Gaskets 7 are provided at the openings 8, 9, 10 at which the flat conductor 2 and/or the conductor 4 exit the housing. Similar types of gaskets 7 (not shown) are also provided on the upper shell 51. The gaskets 7 may be produced together with the housing 5 by 2C injection molding. The material of the housing 5 differs from that of the gasket 7. For example, the housing 5 may be made of fiberglass-reinforced polyamide, while the gasket may be made of a thermoplastic elastomer (TPE) or ethylene propylene diene rubber (EPDM).

[0037] FIG. 5 illustrates the sealing action. The gasket 7 for the conductor 4 is shown as an example. The gaskets 7 for the two shells 51, 52 are U-shaped. When the upper shell is fitted onto the lower shell the ends of the gaskets overlap considerably. Furthermore, the gaskets 7 are arranged adjacent to and touching one another along the longitudinal expanse of the conductor 4. The upper shell 52 along the flat conductor 2 is also slightly longer than the lower shell 51.

[0038] A further sealing measure is seen in FIG. 4, which shows a cross-section of the upper shell 51. The shell 51 includes the female profile 54 for a screw head. In addition, a detent lug of the latch 57, for interaction with the bracket of the lower shell 52, and drip rims 59 are provided on the side walls of the shell 51. The drip rims 59 are located on the lower end of the side wall and taper outwardly to a point. Any moisture running off the outside of the upper shell 51 would collect and drip off at the particular drip rim 59 instead of being drawn by capillary forces into the gap between the shells 51, 52.

[0039] The contact point 1 of the present disclosure has been explained on the basis of a single-layer flat conductor. However, the contact point could also be embodied for multi-layer flat conductors. For example, a uniform housing 5 may be used for terminals of any of the several layers of a flat conductor, and the contact element 3 may be in centric alignment with the flat conductor 2. Moreover, the particular terminal part would compensate the difference in height. Thus, the terminal part may be perpendicular to the narrow side of the flat conductor 2 and may also have a bent or inclined section to enable it to reach the vertical center of the flat conductor and the contact element 3. The bend or incline, however, should be arranged outside of the aluminum/copper transition.

[0040] In some embodiments, it is also contemplated to use the flat conductor shown in FIGS. 1-5 for every layer of the multi-layer flat conductor, if a cavity for a shell 51, 52 of the housing 5 is provided between the layers in the terminal area 11 of the flat conductor. For example, this could be done by partially spacing the layers apart in the terminal area 11.

[0041] The drawings merely depict schematic representations and serve only to illustrate the present disclosure. The same or similar elements are provided throughout with the same reference numbers.

[0042] Having described aspects of the present disclosure in detail, it will be apparent that modifications and variations are possible without departing from the scope of aspects of the present disclosure as defined in the appended claims. As various changes could be made in the above constructions, products, and methods without departing from the scope of aspects of the present disclosure, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.

LIST OF REFERENCE NUMBERS

[0043] contact point 1

[0044] flat conductor 2

[0045] contact element 3

[0046] conductor 4

[0047] housing 5

[0048] fuse 6

[0049] gasket 7

[0050] openings 8, 9, 10

[0051] terminal area 11

[0052] screw connections 21, 22

[0053] shells 51, 52

[0054] inner side 53

[0055] female profiles 54, 55

[0056] dehumidifying port 56

[0057] latch 57, 58

[0058] drip rim 59

[0059] detent lugs 60