ELECTRICAL CONTACT TERMINAL FOR AN ELECTRICAL PLUG CONNECTOR FOR A SAFETY RESTRAINT SYSTEM

Abstract

An electrical contact terminal for an electrical plug connector for a safety restraint system is made from a single piece of bent and cut sheet-metal. The electrical contact terminal includes a mating end, having at least one contact face adapted for electrically contacting a corresponding counter contact of a counter connector. The mating end defines a mating direction of the electrical contact terminal. The electrical contact terminal includes a mounting end, having a mounting face adapted for being electrically connected to a cable end of an electrical cable. The mounting end defines a cable extension direction of the electrical contact terminal. The electrical contact terminal includes a shorting clip portion and an anchor leg, including a first abutment face. The first abutment face is a cut face of the sheet metal a surface normal of the first abutment face faces in the cable extension direction.

Claims

1. An electrical contact terminal for an electrical plug connector for a safety restraint system, wherein the electrical contact terminal is made from a single piece of bent and cut sheet-metal, the electrical contact terminal comprising: a mating end, having at least one contact face configured for electrically contacting a corresponding counter contact of a counter connector, wherein the mating end defines a mating direction of the electrical contact terminal; a mounting end, having a mounting face configured for being electrically connected to a cable end of an electrical cable, wherein the mounting end defines a cable extension direction of the electrical contact terminal; a shorting clip portion that is configured to short-circuit the electrical contact terminal with a further electrical contact terminal, if the electrical contact terminal is provided in an electrical plug connector and if the electrical plug connector is in an uncoupled or incorrectly coupled condition; and an anchor leg, including a first abutment face that is a cut face of the sheet metal, and wherein a surface normal of the first abutment face faces in the cable extension direction.

2. The electrical contact terminal of claim 1, wherein the anchor leg includes a first bearing face that is a cut face of the sheet metal, and a surface normal of the first bearing face faces in the mating direction.

3. The electrical contact terminal according to claim 1, wherein the anchor leg extends in the mating direction, the anchor leg includes an anchor protrusion extending in the cable extension direction, and the first abutment face and/or the first bearing face are provided on the anchor protrusion.

4. The electrical contact terminal according to claim 1, wherein the anchor leg comprises at least one embossed stiffening element.

5. The electrical contact terminal according to claim 1, wherein the electrical contact terminal comprises a fixing plate part, including a second abutment face that is a main face of the sheet metal, and a surface normal of the second abutment face faces in the cable extension direction.

6. The electrical contact terminal according to claim 5, wherein the fixing plate part includes a test contact portion.

7. The electrical contact terminal according to claim 1, comprising a bearing protrusion arranged on a bearing end of the electrical contact terminal, opposite to the mounting end, and wherein the bearing protrusion includes a second bearing face, the second bearing face is a cut face of the sheet metal, and a surface normal of the second bearing face faces in the mating direction.

8. The electrical contact terminal according to claim 1, wherein the mounting end is a welding end, and the mounting face is adapted for being welded to a cable end of an electrical cable.

9. An electrical plug connector for a safety restraint system, comprising: a first electrical contact terminal according to claim 1; a second electrical contact terminal according to claim 1; and a housing including a receiving portion that at least partly receives the first and second electrical contact terminals so that a shorting clip portion of the first electrical contact terminal and a shorting clip portion of the second electrical contact terminal form a shorting clip that short-circuits the electrical contact terminals, if the electrical plug connector is in an uncoupled or incorrectly coupled condition, and wherein the housing comprises at least one first contrary abutment face and/or at least one first contrary bearing face, the first contrary abutment face abuts at least the first abutment face of one of the electrical contact terminals, and the first contrary bearing face supports at least the first bearing face of one of the electrical contact terminals.

10. The electrical plug connector according to claim 9, wherein the housing further comprises at least one second contrary bearing face that supports at least the second bearing face of one of the electrical contact terminals.

11. The electrical plug connector according to claim 9, comprising a cover that is coupled to the housing and covers the receiving portion, and wherein the cover includes at least one positioning recess, the positioning recess at least partly receives the fixing plate part of one of the electrical contact terminals, and the positioning recess forms a second contrary abutment face that abuts the second abutment face of the electrical contact terminal whose fixing plate part is received in the positioning recess.

12. The electrical plug connector according to claim 11, wherein the cover includes a clamping protrusion that clamps the mounting end of the received electrical contact terminal with the housing.

13. The electrical plug connector according to claim 9, comprising a secondary locking member, which is insertable into the housing of the electrical plug connector and which upon full insertion into the housing of the plug connector separates the short-circuiting contact between the at least two shorting clip portions that form the shorting clip.

14. The electrical plug connector according claim 9, wherein the short-circuiting contact between the at least two shorting clip portions that form the shorting clip is adapted to be separated upon correct coupling of the plug connector to a corresponding counter-connector, due to a mechanical contact with a separator portion of the counter-connector.

15. A method for assembling an electrical plug connector according to claim 9, the method comprising: inserting the electrical contact terminals in a receiving portion of the housing so that a shorting clip portion of the first electrical contact terminal and a shorting clip portion of the second electrical contact terminal form a shorting clip that short-circuits the electrical contact terminals, if electrical plug connector is in an uncoupled or incorrectly coupled condition, and so that a first contrary abutment face of the housing abuts at least the first abutment face of one of the electrical contact terminals.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0039] In the following, at least one embodiment of the invention is described exemplarily with reference to the enclosed figures, in which:

[0040] FIG. 1 shows a schematic exploded view of an electrical plug connector;

[0041] FIG. 2A shows a schematic perspective view of an electrical plug connector, wherein the cover and the CPA are removed;

[0042] FIG. 2B shows a schematic perspective view of an electrical plug connector;

[0043] FIG. 3 shows a schematic top view (in a mating direction) of two adjacent electrical contact terminals connected to cables;

[0044] FIG. 4 shows a schematic perspective view of two adjacent electrical contact terminals;

[0045] FIG. 5 shows a schematic perspective view of a single electrical contact terminal;

[0046] FIG. 6 shows a schematic cut view of an electrical plug connector cut through a first contrary abutment face of the housing;

[0047] FIG. 7 shows a schematic cut view of an electrical plug connector cut through a clamping protrusion of the cover;

[0048] FIG. 8 shows a schematic cut view of an electrical plug connector cut through a positioning recess of the cover; and

[0049] FIG. 9 shows a schematic cut view of an electrical plug connector laterally cut.

DETAILED DESCRIPTION

[0050] FIG. 1 shows a schematic exploded view of an electrical connector 10. The plug connector comprises a housing 400. The housing 400 has a receiving portion that is adapted to at least partially receive a first electrical contact terminal 500a and a second electrical contact terminal 500b. Those terminals 500a, 500b will be described with greater detail with respect to FIGS. 4 and 5.

[0051] The electrical contact terminals 500a, 500b are electrically connected to cables 600a, 600b. After being received within the housing, the housing 400 can be covered by a cover 200, wherein the cover 200 is coupled to the housing 400 e.g. by locking means. Alternatively, the housing could be permanently fixed to the cover, e.g. by gluing or welding. Further, the electrical plug connector 10 comprises a secondary locking member 100 (also referenced as connector position assurance member (CPA)). The secondary locking member 100 is insertable into the cover 200 and the housing 400 of the plug connector 10. Upon full insertion into the housing 400 the secondary locking member 100 may separate a short-circuiting contact between the at least two shorting clip portions 530a, 530b that form the shorting clip 530 (cf. FIG. 3).

[0052] FIG. 2A shows the housing 400 of the electrical plug connector 10, wherein the electrical contact terminals 500a, 500b are received within the housing. The respective cable 600a, 600b, which are coupled to individual ones of the electrical contact terminals 500a, 500b are received within a cable recess of the housing 400 and extend in cable extension direction C, wherein the cable extension direction C faces away from the housing 400 of the plug connector 10.

[0053] FIG. 2B is a schematic perspective view of an electrical plug connector 10, as described with reference to FIGS. 1 and 2A. The housing 400 is covered by a cover 200 and a secondary locking member (CPA) 100 is inserted into the housing 400 and the cover 200. In the configuration shown in FIG. 2B, the electrical plug connector 10 is in an uncoupled or incorrectly coupled condition and the secondary locking member 100 is not locked. This can be seen in that the secondary locking member 100 is protruding from the backside of the electrical plug connector 10, respectively from the backside of the cover 200. In case the plug connector is properly connected to this counterpart, the secondary locking member CPA 100 can be further inserted into the housing and will be substantially flush with the backside of the cover 200. Thus, there is a visual feedback for a correct coupling of the plug connector 10. Further, the correct coupling can be monitored electrically or electronically, as the CPA 100 will open a short-circuiting contact of the shorting clip 530 between the first and second electrical contact terminals 500a, 500b.

[0054] FIG. 3 shows a perspective top view (in mating direction A) of two adjacent electrical contact terminals 500a, 500b. The configuration shown in FIG. 3 corresponds to the configuration of the electrical contact terminals within the housing 400 of the plug connector 10. Here, a shorting clip portion 530a of the first electrical contact terminal 500a electrically contacts a shorting clip portion 530b of the electrical contact terminal 500b via shorting faces and thereby short-circuiting these terminals. In case the electrical plug connector 10 is correctly coupled to its counterpart, the shorting clip can be opened.

[0055] FIG. 4 shows a schematic perspective view of two adjacent electrical contact terminals 500a, 500b. The contact terminal 500a is shown in greater detail in a perspective view in FIG. 5. Generally, the first electrical contact terminal 500a and the electrical contact terminal 500b are formed symmetrically. Thus, the features of an electrical contact terminal will now be described with reference to FIG. 5. All features of the electrical contact terminal 500a are referenced with a reference sign containing small letter a. However, all these features are also present in the second electrical contact terminal 500b. Same features have the same reference sign wherein the features of the first contact terminal are marked with a small letter a and the features of the second electrical contact terminal 500b are marked with a small letter b.

[0056] FIG. 5 shows a schematic prospective view of a single electrical contact terminal 500a. The following description is respectively valid for the second electrical contact terminal 500b. The electrical contact terminal 500a comprises a mating end 510a for electrically 25 contacting and receiving an electrical contact of a corresponding counter connector such as a contact pin. The mating end 510a comprises a contact face 512a, which is in electrical contact with a corresponding electrical contact pin of a corresponding counter connector, if plug connector is electrically coupled to the corresponding counter connector. The contact face 512a may be plated with a Ni-containing alloy and/or an Au-containing alloy to improve the conductivity of the electrical contact and to provide oxidation resistance.

[0057] The extension of the mating end defines the mating direction A of the electrical contact terminal 500a and therefore of the electrical plug connector. In an upper section, the mating end 510a has a substantially cylindrical form, wherein a first bent portion 561a extends laterally. The first bent portion 561a connects the mating end 510a with a bearing protrusion 570a. The bearing protrusion 570a is arranged on a bearing end of the electrical contact terminal 500a that is particularly opposite to the mounting end 520a.

[0058] The bearing protrusion 570a includes a second bearing face 575a that is a cut face of the sheet metal. A surface normal of the second bearing face 575a faces in mating direction A. The second bearing face 575a can be supported by a second contrary bearing face of the electrical plug connector, thereby defining the position of the electrical contact terminal 500a within the plug connector housing 400 in mating direction A (cf. FIG. 6).

[0059] The bearing protrusion 570a is connected via second and third bent portions 562a, 563a with a shorting clip portion 530a of the electrical contact terminal 500a. The shorting clip portion 530a includes a flexible arm 534a and a shorting face 532a. Further, the flexible arm 534a provides a contact force to close the shorting clip 530 and to maintain the shorting clip 530 in closed condition, e.g. under external forces, such as vibration.

[0060] Further, the electrical contact terminal 500a comprises an anchor leg 540a that is separate from the flexible arm 534a. The main plane of the anchor leg 540a may be arranged so as to be parallel to the mating direction A and a cable extension direction C, defined by the extension direction of the mounting end 520a of the electrical contact terminal 500a. The anchor leg 540a extends in mating direction A and comprises an anchor protrusion 542a. The anchor protrusion 542a extends in cable direction C.

[0061] A first abutment face 544a is provided at the anchor protrusion 542a and is a cut face of the sheet metal. The surface normal of the first abutment face 544a faces in cable extension direction C. Thus, a stiffness of the anchor leg 540a in direction of the cable extension direction C can be designed by designing the shape of the anchor leg 540a, as the stiffness is dependent on the second momentum of area of the anchor leg and therefore of the cut or punch design of the anchor leg 540a.

[0062] Further, the anchor protrusion 542a includes a first bearing face 545a that can be supported by a first contrary bearing face 445 of the plug connector housing 400 (cf. FIG. 6), thereby precisely positioning the electrical contact terminal 500a in mating direction A. By providing first and second bearing faces 545a and 575a, an undesired tilting of the electrical contact terminal 500a within the housing of the plug connector can be prevented. Further, the anchor leg 540a may include stiffening elements 547a which are provided in form of embossed elements. These embossed elements may be embossed in different sides of the anchor leg 540a, thereby further stiffening the anchor leg.

[0063] The electrical contact terminal 500a further comprises a fixing plate part 550a that is connected to the anchor leg 540a via fourth and fifth bent portions 564a, 565a. The fixing plate part 550a includes a second abutment face 552a that is formed by the main face of the sheet metal. The surface normal of the second abutment face 552a faces in cable extension direction C. The second abutment face is adapted to abut with a second contrary abutment face 252 of the cover 200 of the plug connector 10 and thereby increasing the allowable extension forces (cf. FIG. 9).

[0064] A mounting end 520a of the electrical contact terminal 500a is connected to the fixing plate part 550a via sixth bent portion 566a. Accordingly, the fixing plate part 550a is provided in close proximity to the mounting end 520a of the electrical contact terminal 500a. Thereby, a pulling force that is applied on the cable or on the mounting end 520a can be guided to the cover 200 and/or the housing 400 of the plug connector 10 via the second abutment face 552a of the fixing plate part 550a. Thus, the electrical contact terminal 500a is less prone to undesired displacement, plastic deformation and breakage.

[0065] The fixing plate part 550a may include a test contact portion 553a that can be electrically contacted e.g. monitoring the correct coupling of the electrical plug connector, as described above. Further, the fixing plate part 550a may comprise a gripping portion 555a that serves for gripping the electrical contact terminal 500a during an assembly process. With providing a distinct gripping portion 555a, no electrically functional relevant parts (such as mating end, mounting end or shorting clip portion) need to be gripped, thereby reducing the risk of negatively affecting the mounting face 526a, the contact face 512a and/or the shorting face 532a of the electrical contact terminal 500a.

[0066] Further, the electrical contact terminal 500a and in particular the mounting end 520a comprises a mounting surface 526a that can be plated with an Sn containing alloy. This mounting face 526a can be welded to a cable end 626a of cable 600a as shown in FIG. 3.

[0067] In the following reference signs are used without small letters a or b. Thus, the following description is valid for first and second electrical contact terminals. FIG. 6 shows a schematic cut view of an electrical plug connector 10 being cut through a first contrary abutment face 445 of the housing 400 of a plug connector 10.

[0068] As shown in FIG. 6, the first abutment face 545 of the electrical contact terminal 500 abuts the first contrary abutment face 445 of the housing 400. Thus, in case a pulling force is applied to cable 600 in cable extension direction C, the first abutment face 545 serves to guide the pulling force to the housing 400 of the plug connector 10. Accordingly, the likelihood of undesired displacement, deformation or breakage of the electrical terminal can be reduced, and the allowable retention force can be increased.

[0069] Further, the first abutment face allows an exact positioning of the electrical contact terminal 500 within the housing 400 in cable extension direction C. Further, the first bearing face 545 of the electrical contact terminal 500 is supported by the first contrary bearing face 445 of the housing 400, thereby positioning the electrical contact terminal 500 exactly in a mating direction A. On a front end of the electrical contact terminal 500 a bearing protrusion 570 is provided heaving a second bearing face 575. The second bearing face 575 is supported by a second contrary bearing face 475 of the housing 400. Thus, the electrical contact terminal is precisely positioned within the housing mating direction A and tilting of the terminal 500 can be avoided.

[0070] FIG. 7 shows a schematic cut view of an electrical plug connector 10 being cut through a clamping protrusion 226 of the cover 200. In case the cover 200 is coupled to the housing 400, the clamping protrusion 226 clamps the mounting end 520, respectively the mounting face 526 and the thereon connected cable end 626 of cable 600 with a cover 200. A pulling force applied on the cable 600 in cable extension direction C can be guided via the clamping protrusion 226 to the housing and/or the cover and thereby a displacement, a plastic deformation or breakage of the electrical contact terminal can be effectively avoided.

[0071] FIG. 8 shows a schematic cut view of an electrical plug connector 10 being cut through a positioning recess 250 of the cover 200. The positioning recess 250 at least partly receives the fixing plate part 550a, b of the respective electrical contact terminals 500a, 500b. The cover 200 may comprise a single positioning recess 250 or separate positioning recesses. The positioning recess 250 forms a second contrary abutment face 252 that abuts the second abutment face 552 of the electrical contact terminal 500, whose fixing plate part 550 is received in the positioning recess 250. Thereby, the allowable retention force can be further increased, and the likelihood of an undesired displacement, deformation or breakage of the electrical contact terminal 500 can be reduced. Further, the test contact portions 553a and 553b are accessible through respective openings in the housing 400, thereby allowing an electric or electronic monitoring of the correct coupling of the electrical plug connector.

[0072] FIG. 9 shows a schematic cut view of an electrical plug connector 10, wherein the housing is not shown. As depicted in FIG. 9, the fixing plate part 550 of the electrical contact terminal 500 is received within the positioning recess 250 of the cover and the second abutment face 552 abuts the second contrary abutment face 252 of the cover 200.

[0073] The preceding description is exemplary rather than limiting in nature. Variations and modifications to the disclosed examples may become apparent to those skilled in the art that do not necessarily depart from the essence of this invention. The scope of legal protection given to this invention can only be determined by studying the following claims.