Connecting plug and socket with lamella basket

Abstract

A socket comprises an annular socket part and a lamella basket at least partly disposed in the interior of the annular socket part. The lamella basket comprises a plurality of lamellae and an annular carrier strip located at the rear part of the lamella basket. Each of the lamellae has a first end and a second end, with the first end being firmly attached to, or integrally moulded with, the annular carrier strip and with the second end being implemented as a free end. The lamellae extend from the annular carrier strip towards the front end of the socket. The inner surface of the annular socket part comprises a bulge that: protrudes in a radially inward direction; and is configured for supporting the lamellae when the lamellae are resiliently deformed in a radially outward direction.

Claims

1. A socket comprising: an annular socket part; and a lamella basket at least partly disposed in an interior of the annular socket part, the lamella basket comprising a plurality of lamellae and an annular carrier strip located at a rear portion of the lamella basket, each of the lamellae having a first end and a second end, with the first end being firmly attached to, or integrally moulded with, the annular carrier strip and with the second end being implemented as a free end, with the lamellae extending from the annular carrier strip towards a front end of the socket, wherein an inner surface of the annular socket part comprises a bulge that protrudes in a radially inward direction, wherein the bulge of the annular socket part is configured for supporting the lamellae when the lamellae are resiliently deformed in a radially outward direction.

2. The socket according to claim 1, wherein the lamellae extend from the annular carrier strip along the inner surface of the annular socket part towards the front end of the socket.

3. The socket according to claim 1, wherein a contour of the annular socket part's inner surface corresponds to a contour of a rear side of the resiliently deformed lamellae.

4. The socket according to claim 1, wherein a contour of the annular socket part's inner surface corresponds to a deflection curve of the resiliently deformed lamellae.

5. The socket according to claim 1, wherein at least one of the lamellae comprises a bulge that protrudes in a radially inward direction.

6. The socket according to claim 1, wherein the inner surface of the annular socket part is configured to act as a supporting surface for the lamellae when the lamellae are resiliently deformed in a radially outward direction.

7. The socket according to claim 1, wherein the lamella basket comprises a plurality of welding straps disposed at a rear end of the lamella basket.

8. The socket according to claim 7, wherein the welding straps are configured for being welded to the annular socket part at a plurality of welding spots.

9. The socket according to claim 1, wherein the socket comprises a press ring arranged in the interior of the lamella basket, the press ring being configured for pressing the annular carrier strip against the annular socket part.

10. The socket according to claim 1, wherein the annular socket part is formed by deep drawing.

11. The socket according to claim 1, wherein a contour of the inner surface of the annular socket part is obtained by subjecting the inner surface of the annular socket part to an embossing process.

12. A connecting plug comprising: a lamella basket comprising a plurality of lamellae, each of the lamellae having a first end and a second end, the first end being fixed and the second end being implemented as a free end; a holding element comprising a central body disposed in the interior of a lamella basket and a cap attached at or integrally moulded with a front end of the central body, the cap having a protruding edge that projects from the central body in a radially outward direction, wherein the cap is shaped and configured for accommodating the respective second ends of the lamellae; and a base part, with a rear portion of the lamella basket being attached to the base part, wherein the lamella basket further comprises an annular carrier strip located at the rear portion of the lamella basket, with the first end of each of the lamellae being firmly attached to, or integrally moulded with, the annular carrier strip, wherein the lamellae extend from the annular carrier strip to the holding element's cap.

13. The connecting plug of claim 12, wherein the cap consists of electrically insulating material.

14. A connecting plug comprising: a lamella basket comprising a plurality of lamellae, each of the lamellae having a first end and a second end, the first end being fixed and the second end being implemented as a free end; a holding element comprising a central body disposed in an interior of the lamella basket and a cap attached at, or integrally moulded with, a front end of the central body, the cap having a protruding edge that projects from the central body in a radially outward direction, wherein the cap is shaped and configured for accommodating the respective second ends of the lamellae, and a base part, with a rear part of the lamella basket being attached to the base part, wherein the connecting plug further comprises a supporting sleeve arranged in the interspace between the lamella basket and the holding element, the supporting sleeve being configured and shaped for providing a support for the lamellae resiliently by means of supporting lamellae.

15. A plug-in connector comprising a connecting plug according to claim 12 and a socket, the connecting plug being adapted for being plugged into the socket and for establishing an electrical connection with the socket.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The invention is illustrated in greater detail with the aid of schematic drawings.

(2) The drawings show schematically:

(3) FIG. 1 shows two different views of a connecting plug.

(4) FIG. 2 shows a cross-sectional view of the connecting plug.

(5) FIG. 3 shows a perspective view of the lamella basket.

(6) FIG. 4 shows a plug-in connector comprising a connecting plug and a socket.

(7) FIG. 5 shows a perspective view of a socket with a lamella basket together with a connecting plug.

(8) FIG. 6 shows a cross-sectional view of the socket with a lamella basket together with a connecting plug.

(9) FIG. 7A shows how the connecting plug is inserted into the socket.

(10) FIG. 7B shows how an electric contact between the connecting plug and the socket's lamella basket is established.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

(11) In the following description of preferred embodiments of the present invention, identical reference numerals denote identical or comparable components.

(12) FIG. 1 shows two perspective views of a connecting plug 1 according to embodiments of the present invention. The connecting plug 1 comprises a base element 2 with a circumferential flange 3, a lamella basket 4 with a plurality of lamellae 5 and a ring-shaped cap 6 disposed at the connecting plug's front face. The connecting plug 1 is configured for being inserted into a corresponding socket. When the connecting plug 1 is plugged into the socket, the lamellae 5 are pressed against the lateral walls of the socket and establish an electrical connection between the connecting plug 1 and the socket.

(13) FIG. 2 shows a cross-sectional view of the connecting plug 1 and its components. The connecting plug 1 comprises the base element 2, the lamella basket 4 with the plurality of lamellae 5 and a holding element 7 with the ring-shaped cap 6. The connecting plug 1 further comprises a supporting sleeve 8 disposed in the interspace between the lamella basket 4 and the holding element 7. The lamella basket 4 comprises an annular carrier strip 9 and a plurality of lamellae 5. The mating direction 10 of the connecting plug 1 is indicated with an arrow. When viewed in the mating direction 10 of the connecting plug 1, the annular carrier strip 9 of the lamella basket 4 is disposed at the rear end of the lamella basket 4, with the lamellae 5 extending from the annular carrier strip 9 to the ring-shaped cap 6 predominantly in the mating direction 10 of the connecting plug 1. For each lamella 5, only the respective first end 11 is affixed to the annular carrier strip 9, whereas the second end 12 is implemented as a free end. The lamellae 5 are implemented as resilient metal strips and accordingly, each lamella 5 can be elastically deformed in a radially inward direction.

(14) In FIG. 3, a perspective view of the lamella basket 4 is given, wherein the annular carrier strip 9 and the plurality of lamellae 5 are shown. It can be seen that each of the lamellae 5 is connected at its respective first end 11 to the annular carrier strip 9, whereas the second end 12 of each lamella 5 is a free end. Thus, the lamellae 5 are resiliently supported by the annular carrier strip 9. The lamellae 5 extend predominantly in the mating direction 10 of the connecting plug 1 towards the front end of the connecting plug 1. In a preferred embodiment, the annular carrier strip 9 and the lamellae 5 are integrally formed in one piece. Preferably, the lamella basket 4 is formed as a stamped part.

(15) Each of the lamellae 5 has a contact area 13, 14 that stands out in the radially outward direction of the lamella basket. The contact areas 13, 14 are implemented as bulges that protrude in the radially outward direction. Preferably, the contact areas of different sets of lamellae 5 are located at different longitudinal positions when viewed in the mating direction 10 of the connecting plug 1. For example, for a first subset of lamellae, the lamellae's contact areas 13 are located at a first longitudinal position, wherein for a second subset of lamellae 5, the lamellae's contact areas 14 are located at a second longitudinal position, with the first longitudinal position being different from the second longitudinal position. As shown in FIG. 3, the lamellae with the contact area 13 at the first longitudinal position are disposed alternatingly with the lamellae having the contact areas 14 at a respective second longitudinal position. By arranging the contact areas of the lamellae 5 at different longitudinal positions, the mechanical resistance for inserting the connecting plug 1 into a corresponding socket is reduced. When the connecting plug 1 is inserted into the socket in the connecting plug's mating direction 10, first, the lamellae with the contact areas 13 at the first longitudinal position are pressed in a radially inward direction. When the connecting plug 1 is further inserted into the corresponding socket, the lamellae 5 with the contact areas 14 located at the respective second longitudinal positions are pressed in the radially inward direction. Instead of deforming all the lamellae 5 at the same time, different subsets of the lamellae are deformed one after the other and thus, the overall mechanical resistance is decreased and the insertion force is reduced. In the example shown in FIGS. 2 and 3, the contact areas 13, 14 are located at two different longitudinal positions, but they may as well be located at three or more longitudinal positions.

(16) The lamella basket 4 consists of conductive material. The lamella basket 4 may for example consist of metal, for example of a copper alloy such as for example a copper-nickel (CuNi) alloy or a copper-chromium (CuCr) alloy. In order to provide for an improved electrical contact, the lamella basket 4 may be subjected to plating, for example with gold, silver or copper. Additionally or alternatively, the base element 2 may be subjected to plating as well. The lamella basket 4 may be formed as a stamped part, for example as a stamp-rolled part or as a stamp-bent part. In particular, the lamella basket 4 shown in FIG. 3 can be formed by manufacturing a lamella strip and bending the lamella strip in a way that the lamella basket 4 is obtained.

(17) As shown in FIG. 2, the connecting plug 1 further comprises a holding element 7 that is at least partly disposed in the interior of the lamella basket 4. The holding element 7 comprises a central sleeve 15 and the ring-shaped cap 6 arranged at the front end of the connecting plug 1. The ring-shaped cap 6 and the central sleeve 15 may be formed in one piece. For example, the ring-shaped cap 6 and the central sleeve 15 may be integrally moulded. Alternatively, the ring-shaped cap 6 and the central sleeve 15 can be formed as separate parts.

(18) The ring-shaped cap 6 has a protruding edge that projects from the central sleeve 15 in a radially outward direction. At the rear side of the ring-shaped cap 6, a circumferential groove 16 is located, said groove 16 being configured for accommodating the respective second ends 12 of the lamellae 5. When inserting the holding element 7 into the interior of the lamella basket 4, the second ends 12 of the lamellae 5 are introduced into the circumferential groove 16. Thus, the respective second ends 12 of the lamellae 5 are held in place by the sidewalls of the groove 16, wherein a certain moving space for the second ends 12 is provided. Instead of a groove 16, a recess or one or more indentations may be located at the rear side of the ring-shaped cap 6.

(19) Preferably, for inserting the second ends 12 of the lamellae 5 into the groove 16, the lamellae 5 have to be slightly deformed in a radially inward direction such that the lamellae 5 are pretensioned. Due to this pretension, the alignment of the lamellae 5 is improved. The protruding edge of the ring-shaped cap 6 covers the respective second ends 12 of the lamellae 5. The protruding edge prevents that any kind of counterpart can be inserted into an interspace between the lamellae 5 and the holding element 7, which may deform and damage the lamellae 5. Thus, the ring-shaped cap 6 protects the lamellae 5 from damages.

(20) The ring-shaped cap 6 provides a touch protection at the front face of the connecting plug 1. The ring-shaped cap 6 and preferably the entire holding element 7 may consist of insulating material like for example a plastic material, a polymer material, an elastomer like for example natural rubber or synthetic rubber, etc. The ring-shaped cap 6 and preferably the entire holding element 7 can be formed by injection moulding. The ring-shaped cap 6 serves as a touch protection at the front face of the connecting plug 1. In case a user inadvertently touches the connecting plug's front face, he or she will not get in contact with live parts of the connecting plug 1.

(21) The base part 2 comprises a receptacle 17 that may for example be implemented as a cylindrical opening. The receptacle 17 is configured for accommodating the annular carrier strip 9 of the lamella basket 4.

(22) The connecting plug 1 further comprises a supporting sleeve 8 disposed in the interspace between the central sleeve 15 and the lamella basket 4. The supporting sleeve 8 comprises a ring-shaped rear part 20 configured for being accommodated in the receptacle 17 of the base element 2. From the rear part 20, the supporting sleeve 8 extends in the direction towards the cap 6 of the holding element 7. The supporting sleeve 8 may for example extend up to the contact areas 13, 14 of the lamellae 5. The supporting sleeve 8 is configured for providing a rigid support for the lamellae 5. In particular, in case the connecting plug is inserted into a socket in a slanted direction, the rim of the socket may exert a force on the lamellae 5 and may cause a deformation of the lamellae 5 in a radially inward direction. Due to the presence of the rigid supporting sleeve 8, any plastic deformation of the lamellae 5 is prevented. The presence of the supporting sleeve 8 ensures that the lamellae 5 maintain their shape during use of the connecting plug 1. Preferably, the lamella basket 4, the supporting sleeve 8 and the holding element 7 are implemented as rotationally symmetric components. Further preferably, the lamella basket 4, the supporting sleeve 8 and the holding element 7 are arranged coaxially with regard to the mating direction 10 of the connecting plug 1. Preferably, the supporting sleeve 8 consists of metal, for example of stainless steel. The supporting sleeve 8 may for example be formed by turning or by deep drawing.

(23) According to a preferred embodiment which is not shown in the figures, the supporting sleeve may comprise a plurality of supporting lamellae, with the supporting lamellae of the supporting sleeve providing a resilient support for the lamellae 5 of the lamella basket 4. Because of the additional resilient support, the contact force required for deforming the lamellae 5 is increased. The advantage of this embodiment is that the relaxation resistance of the lamellae 5 is improved, which means that the spring force of the lamellae 5 can be maintained for a long period of time. This allows for realising a high-performance connector configured for ensuring reliable operation for an extended period of time. In particular, this embodiment allows increasing the upper limit temperature to more than 200° C.

(24) The connecting plug 1 further comprises the base element 2 configured for holding the lamella basket 4, the supporting sleeve 8 and the holding element 7. The base element 2 comprises the receptacle 17, the receptacle 17 being configured for accommodating the annular carrier strip 9 of the lamella basket 4, the rear part 20 of the supporting sleeve 8 and the rear part of the holding element 7. The annular carrier strip 9 of the lamella basket 4 is fixed by means of a press fit between the encompassment 21 of the receptacle 17 and the rear part 20 of the supporting sleeve 8. In this respect, the rear part 20 of the supporting sleeve 8 serves as a counterpart of the encompassment 21. As shown in FIG. 3, the annular carrier strip 9 of the lamella basket 4 comprises a plurality of creasings 22. These creasings 22 of the annular carrier strip 9 are configured for being deformed when the press fit is established, thereby improving the press fit. As a result, the annular carrier strip 9 of the lamella basket 4 is tightly fixed between the encompassment 21 of the receptacle 17 and the rear part 20 of the supporting sleeve 8.

(25) After the annular carrier strip 9 of the lamella basket 4 and the rear part 20 of the supporting sleeve 8 are fastened, the holding element 7 is inserted into the interior of the lamella basket 4 and the supporting sleeve 8. The base element 2 comprises a connecting element 19 configured for fixing the holding element 7, and at the rear end of the holding element 7, a bore hole 18 is located. When the holding element 7 is inserted, the connecting element 19 extends through the bore hole 18. Then, the holding element 7 can be fixed by subjecting the connecting element 19 to a shaping technique like for example flanging.

(26) The base element 2 may further comprise a circumferential flange 3 and a bore hole 23 disposed at the rear face of the base element 2. The bore hole 23 may be configured for mounting the connecting plug 1 by means of a thread-forming screw. The base element 2 may be made of metal, preferably of a copper alloy, such as for example brass or a copper-tellurium (CuTeP) alloy. The base element 2 may be formed by turning or by impact extrusion.

(27) According to an alternative embodiment which is not shown in the figures, the supporting sleeve 8 only consists of the ring-shaped rear part 20 and does not extend towards the connecting plug's front end. In this embodiment, the supporting sleeve 8 is provided to serve as a counterpart of the encompassment 21 for establishing a tight press fit. The supporting sleeve does not act as a support for the lamellae 5.

(28) FIG. 4 shows a plug-in connector, with the plug-in connector comprising the connecting plug 1 and a corresponding socket 24. The socket 24 may for example be formed by stamping a metal sheet 25. For electrically connecting the socket 24, a wire 26 may be welded to the metal sheet 25. In FIG. 4, the connecting plug 1 is inserted into the socket 24, with the lamellae 5 of the connecting plug 1 being resiliently deformed in a radially inward direction by the sidewalls of the socket 24. Thus, a reliable electrical contact is established between the contact areas 13, 14 of the lamellae 5 and the sidewalls of the socket 24.

(29) In the embodiment shown in FIGS. 1 to 4, a connecting plug with a lamella basket has been described. Alternatively, the lamella basket may as well be provided on the part of the socket. In FIGS. 5 to 7B, a socket comprising a lamella basket configured for establishing an electrical contact with a connecting plug is shown.

(30) FIG. 5 gives a perspective view and FIG. 6 shows a cross-section of a socket 27 together with a corresponding connecting plug 28. The socket 27 comprises an annular socket part 29 and a contact plate 30 attached to or integrally formed with the annular socket part 29, wherein both the annular socket part 29 and the contact plate 30 consist of conductive material, preferably of metal. For example, the annular socket part 2 and the contact plate 30 may be integrally formed as a deep-drawn part.

(31) The lamella basket 31 is at least partly disposed in the interior of the annular socket part 29. The lamella basket 31 comprises an annular carrier strip 32, a plurality of lamellae 33 and a plurality of outwardly bent straps 34. The outwardly bent straps 34 may for example serve as welding straps. The mating direction 35 of the socket 27 is indicated with an arrow. When viewed in the mating direction 35, the annular carrier strip 32 is located in the rear part of the lamella basket 31.

(32) As shown in FIGS. 7A and 7B, each of the lamellae 33 has a first end 36 and a second end 37, wherein the first end 36 is fixed and the second end 37 is implemented as a free end. The first end 36 of each of the lamellae 33 is firmly attached to or integrally moulded with the annular carrier strip 32. The lamellae 33 extend from the annular carrier strip 32 along the inner side walls of the annular socket part 29 towards the front end of the socket 27. Preferably, each of the lamellae 33 extends from the annular carrier strip 32 towards the front end of the socket 27 predominantly in the mating direction 35. In this regard, the predominant component of the lamellae's orientation is the component in the mating direction 35. Each of the lamellae 33 is a convex curved lamella that stands out in a radially inward direction. Each of the lamellae 33 can be resiliently deformed in a radially outward direction. In case the connecting plug 28 is inserted into the socket 27, the lamellae 33 are resiliently deformed in a radially outward direction, whereby an electrical contact is established between the lamellae 33 and the connecting plug 28.

(33) The lamella basket 31 consists of conductive material, preferably of metal and further preferably of a copper alloy such as for example a copper-nickel (CuNi) alloy or a copper-chromium (CuCr) alloy. The lamella basket 31 may be formed as a stamped part, for example as a stamp-rolled part or as a stamp-bent part. For improving the electrical contact, the lamella basket 31 may be subjected to plating, for example with gold, silver or copper. Additionally or alternatively, the annular socket part 29 and the contact plate 30 may be subjected to plating as well.

(34) For mechanically and electrically connecting the lamella basket 31 with the annular socket part 29, the lamella basket 31 may be welded to the annular socket part 29. In this regard, the outwardly bent straps 34 may serve as welding straps configured for being welded to the rear portion of the annular socket part 29 at a plurality of welding spots. The total area of the welding spots is sufficiently large for establishing an extensive material closure between the lamella basket 31 and the annular socket part 29. Thus, both a mechanical fixing and an electrical connection are established between the lamella basket 31 and the annular socket part 29. According to an alternative solution, the lamella basket 31 may for example be fixed to the annular socket part 29 by means of a press ring. The press ring may for example be configured for circumferentially pressing the annular carrier strip 32 against the annular socket part 29 in a radially outward direction. The press ring may be configured for establishing a press fit between the annular carrier strip 32 and the annular socket part 29.

(35) The contact plate 30 is configured for establishing an electric connection with a cable 38. For example, the contact plate 30 may be electrically connected with a cable lug 39 of the cable 38, wherein a joining technique such as for example ultrasonic welding may be employed.

(36) The connecting plug 28 comprises a base part 40 consisting of conductive material. Viewed in the connecting plug's mating direction 41, the front end of the base part 40 is implemented as a contact portion 42. When the connecting plug 28 is inserted into the socket 27, an electrical contact is established between the contact portion 42 of the connecting plug 28 and the lamellae 33 of the socket 27. The connecting plug 28 further comprises an insulating element 43. The front part of the insulating element 43 is implemented as a ring-shaped cap 44 that protrudes in a radially outward direction and covers the front face of the contact portion 42. The ring-shaped cap 44 is configured for providing a touch protection at the connecting plug's front face. In order to fix the insulating element 43, the contact portion 42 comprises a receptacle configured for accommodating the insulating element 43. Furthermore, the base part 40 comprises a connecting element that extends through a bore hole of the insulating element 43 and allows for fixing the insulating element 43 by means of a joining technique like for example flanging. At the rear end of the base part 40, a bore hole is located, wherein said bore hole may for example be configured for accepting a thread-forming screw.

(37) As shown in FIGS. 7A and 7B, when the connecting plug 28 is inserted into the socket 27, the lamellae 33 are elastically deformed in a radially outward direction. As the connecting plug 28 is further inserted into the socket 27, the lamellae 33 are resiliently pressed against the contact portion 42 such that an electrical contact between the lamella basket 31 and the contact portion 42 is established. Each of the lamellae 33 may for example comprise a first section 45 that tapers in the mating direction 35 of the socket 27, a bulge 46 that stands out in a radially inward direction and a second section 47 that widens in the mating direction 35 of the socket 27, with the second section 47 being configured for accepting the connecting plug 28. The inner surface of the annular socket part 29 and the rear surface of the resiliently deformed lamellae have a complementary shape. Thus, the inner surface of the annular socket part 29 serves as a supporting surface 48 for the lamellae 33 when the lamellae 33 are elastically deformed in a radially outward direction. Preferably, the contour of the supporting surface 48 provided by the annular socket part 29 corresponds to the contour of the rear side of the resiliently deformed lamellae. The inner surface of the annular socket part 29 comprises a circumferential bulge 49, with the longitudinal position of the bulge 49, viewed in the socket's mating direction 35, corresponding to the longitudinal position of the lamellae's bulge 46. The bulge 49 is configured for supporting the bulge 46 of the lamellae 33 when die lamellae 33 are resiliently deformed in a radially outward direction. By providing a supporting surface 48 that matches with the rear surface of the resiliently deformed lamellae, deformation and destruction of the lamellae 33 are prevented.

(38) The annular socket part 29 and the contact plate 30 may be integrally formed as a deep-drawn part, for example by deep-drawing a copper sheet. Then, the contour of the inner surface of the annular socket part can for example be obtained by subjecting the inner surface of the annular socket part to an additional embossing process. For the inner surface of the annular socket part 29, close manufacturing tolerances have to be obeyed to, but in other areas of the deep-drawn part, wide manufacturing tolerances can be accepted.

(39) The features described in the above description, claims and figures can be relevant to the invention in any combination. Their reference numerals in the claims have merely been introduced to facilitate reading of the claims. They are by no means meant to be limiting.

LIST OF REFERENCE NUMERALS

(40) 1 connecting plug 2 base element 3 flange 4 lamella basket 5 lamellae 6 ring-shaped cap 7 holding element 8 supporting sleeve 9 annular carrier strip 10 mating direction of the connecting plug 11 first end of lamella 12 second end of lamella 13 contact area of first subset of lamellae 14 contact area of second subset of lamellae 15 central sleeve 16 groove 17 receptacle 18 bore hole 19 connecting element 20 rear part of supporting sleeve 21 encompassment 22 creasings 23 bore hole 24 socket 25 metal sheet 26 wire 27 socket 28 connecting plug 29 annular socket part 30 contact plate 31 lamella basket 32 annular carrier strip 33 lamellae 34 outwardly bent straps 35 mating direction of socket 36 first end of lamellae 37 second end of lamellae 38 cable 39 cable lug 40 base part 41 mating direction of connecting plug 42 contact portion 43 insulating element 44 ring-shaped cap 45 first section of lamellae 46 bulge 47 second section of lamellae 48 supporting surface 49 bulge