Connection Arrangement, Contact Element and Method for Producing a Connection

Abstract

A connection arrangement comprising an electrical cable and a contact element connected to a free end of an electrical conductor of the cable, wherein a first end section of the contact element penetrates an end face of the free end of the electrical conductor, and at least one region of the first end section of the contact element is directly connected to the electrical conductor with a material bond.

Claims

1. A connection arrangement comprising: an electrical cable having an electrical conductor; a contact element connected to a free end of the electrical conductor of the electrical cable, and wherein a first end section of the contact element penetrates an end face of the free end of the electrical conductor; and at least one region of the first end section of the contact element is directly connected to the electrical conductor with a material bond.

2. The connection arrangement of claim 1 and wherein the contact element is connected to the free end of the electrical conductor in such a manner that the contact element does not make contact with an outer circumference of the electrical conductor.

3. The connection arrangement of claim 1 and wherein the electrical conductor is in the form of an inner conductor of the cable, and the contact element is in the form of an inner conductor contact element of a plug connector.

4. The connection arrangement of claim 1 and wherein an outer diameter of the contact element corresponds to an outer diameter of the electrical conductor in a middle section adjoining the first end section of the contact element.

5. The connection arrangement of claim 1 and wherein the connection between the first end section of the contact element and the free end of the electrical conductor is a cold-welded connection.

6. The connection arrangement of claim 1 and wherein a cross section of the first end section tapers in the direction of the free end of the first end section.

7. The connection arrangement of claim 1 and wherein the first end section of the contact element has at least one radial shoulder.

8. The connection arrangement of claim 1 and further comprising: a coating on the contact element.

9. A contact element for connection to a free end of an electrical conductor of an electrical cable comprising: the contact element, having a contact body with a first end section, and wherein the first end section is configured to penetrate an end face of the free end of the electrical conductor; and wherein at least one section of the first end section of the contact body is directly connected to the first conductor with a material bond.

10. (canceled)

11. A method for producing a connection between an electrical conductor of an electrical cable and a contact element, the method comprising the steps: providing a contact element having a first end section; introducing the first end section of the contact element into an end face of a free end of the electrical conductor; and the first end section of the contact element is introduced into the free end of the electrical conductor with high pressure and high relative velocity so that the first end section of the contact element and the electrical conductor are connected to one another with a material bond, at least in certain regions, as a result of the high pressure and the high relative velocity.

12. The method of claim 11 and wherein the high relative velocity is based on a high linear velocity and/or a high angular velocity.

13. The method of claim 11 and wherein the contact element is introduced into the free end of the electrical conductor in such a manner that the contact element does not make contact with an outer circumference of the electrical conductor when the first end section is in position in the electrical conductor.

14. The method of claim 11 and wherein the free end of the electrical conductor forms a completely closed end face that is penetrated by introducing the first end section of the contact element.

15. The method of claim 11 and further comprising: introducing the first end section of the contact element into an end face of the free end of the electrical conductor with a material bond, at least in certain regions, at high velocity and/or with high mechanical force.

16. The connection arrangement of claim 1 and wherein the connection between the first end section of the contact element and the free end of the electrical conductor is a gas-tight connection.

17. The connection arrangement of claim 1 and wherein the first end section of the contact element has at least one radial cutting edge.

18. The connection arrangement of claim 1 and wherein the first end section of the contact element has at least one radial shoulder and an undercut.

19. The method of claim 15 and wherein the material bond created by introducing the first end section of the contact element into an end face of the free end of the electrical conductor is accomplished with high mechanical force.

20. The method of claim 15 and wherein the material bond created by introducing the first end section of the contact element into an end face of the free end of the electrical conductor is accomplished with high velocity and high mechanical force.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0127] Exemplary embodiments of the invention are described in more detail below on the basis of the drawing.

[0128] The figures each show preferred exemplary embodiments in which individual features of the present invention are illustrated in combination with one another. Features of one exemplary embodiment can also be implemented in a manner detached from the other features of the same exemplary embodiment and can accordingly be readily combined with features of other exemplary embodiments by a person skilled in the art to form further useful combinations and sub-combinations.

[0129] In the figures, functionally identical elements are provided with the same reference signs.

[0130] In the drawings:

[0131] FIG. 1 schematically shows an electrical plug connector having a connection arrangement according to the prior art.

[0132] FIG. 2 schematically shows an electrical plug connector comprising a connection arrangement according to the invention.

[0133] FIG. 3 schematically shows a contact element according to the invention having a first end section according to a first embodiment with a rounded free end.

[0134] FIG. 4 schematically shows a contact element according to the invention having a first end section according to a second embodiment with a conical shaped tip.

[0135] FIG. 5 schematically shows a contact element according to the invention having a first end section according to a third embodiment with a tapering cross section.

[0136] FIG. 6 schematically shows a contact element according to the invention having a first end section according to a fourth embodiment with a tapering cross section.

[0137] FIG. 7 schematically shows a contact element according to the invention having a first end section according to a fifth embodiment with a tapering cross section.

[0138] FIG. 8 schematically shows a contact element according to the invention having a first end section according to a sixth embodiment with a radial shoulder.

[0139] FIG. 9 schematically shows a contact element according to the invention having a first end section according to a seventh embodiment with a radial shoulder.

[0140] FIG. 10 schematically shows a contact element according to the invention having a first end section according to an eighth embodiment with a radial shoulder.

[0141] FIG. 11 schematically shows a contact element according to the invention having a first end section according to a ninth embodiment with a radial cutting edge.

[0142] FIG. 12 schematically shows a detailed view of the cutting edge of the contact element from FIG. 11 in a simplified sectional illustration.

[0143] FIG. 13 schematically shows an apparatus for producing a connection arrangement.

DETAILED WRITTEN DESCRIPTION OF THE PREFERRED EMBODIEMENTS

[0144] FIG. 1 shows a perspective sectional view of an electrical plug connector 100 according to the prior art. The electrical plug connector 100 has a connection arrangement 101 comprising an electrical cable 1, a corrugated cable in the exemplary embodiment, and a contact element 102 connected to a free end 2.1 of an electrical conductor 2, the inner conductor of the cable 1 in the present case. The electrical cable 1 has a dielectric 3 which encases the inner conductor or the electrical conductor 2 and electrically isolates it from an outer conductor 4 of the cable 1. The electrical plug connector 100 also has an electrically conductive outer housing 103 which is electrically connected to the outer conductor 4 of the electrical cable 1.

[0145] The connection arrangement 101 from the prior art is electrically and mechanically connected to the electrical conductor 2 or the inner conductor of the cable 1 by means of a soldered connection. For a sufficiently good connection and mechanical stability, the contact element 102 also encloses the free end 2.1 of the electrical conductor 2 on its outer circumference. The remaining intermediate space is filled with a solder. An alternative to a soldered connection can also be a crimp connection according to the prior art.

[0146] A further alternative known from the prior art may involve introducing the contact element 102 into an end face 2.2 of the free end 2.1 of the electrical conductor 2 along a hole (not illustrated) in order to displace the material of the electrical conductor 2 radially outward in order to produce a force-fitting connection to a sleeve encasing the electrical conductor 2.

[0147] In all of the variants mentioned, the problem arises of the production of the connection being comparatively complicated and a sudden change in diameter also being produced in the connection region. An impedance matching operation may become necessary on account of the changed cross section, which can considerably increase the dimensions of the plug connector 100 overall.

[0148] FIG. 2 shows an electrical plug connector 5 according to the invention comprising a connection arrangement 6 according to the invention. The electrical cable 1 corresponds, by way of example, to the corrugated cable already described within the scope of FIG. 1.

[0149] The first end section 7.1 of the contact element 7 according to the invention penetrates the end face 2.2 of the free end 2.1 of the electrical conductor 2 or of the inner conductor of the cable 1. In the exemplary embodiment, the contact element 7 is connected to the free end 2.1 of the electrical conductor 2 in such a manner that the contact element 7 does not make contact with an outer circumference of the electrical conductor 2. In particular, the contact body 7.4 of the contact element 7 does not make contact with the outer circumference of the electrical conductor 2.

[0150] A preferred use of the invention provides for the electrical conductor 2 to be in the form of an inner conductor of the cable 1 and for the contact element 7 to be in the form of an inner conductor contact element of the plug connector 5, as illustrated. The plug connector 5 may have an electrically conductive outer housing 8 and can have any desired design in principle. The exposed second end section 7.5 of the contact element can be designed to make contact with a contact element of a mating plug connector.

[0151] In contrast to the prior art, the contact element 7 can be advantageously formed in one part. It is possible to dispense with a sleeve or a sleeve-like projection of the contact element 102. It is also possible to dispense with the need to supply additional solder to the connection.

[0152] In order to avoid an impedance jump, it may be advantageous if the outer diameter of the contact element 7 corresponds to the outer diameter of the electrical conductor 2 in a middle section 7.2 adjoining the first end section 7.1 of the contact element 7. Finally, an outer conductor contact element surrounding the contact element 7, the electrically conductive outer housing 8 of the plug connector 5 in the present case, can have a constant cross section (not illustrated in the exemplary embodiment) in an axial section which radially surrounds the first end section 7.1 of the contact element 7.

[0153] The connection between the first end section 7.1 of the contact element 7 and the free end 2.1 of the electrical conductor 2 is a direct connection with a material bond at least in certain regions, that is to say a connection with a material bond without additional welding or soldering additives. It is preferably a cold-welded connection, in particular a gas-tight connection. The connection between the first end section 7.1 of the contact element 7 and the free end 2.1 of the electrical conductor 2 is preferably also a form-fitting connection.

[0154] In order to produce the connection between the electrical conductor 2 or the inner conductor of the cable 1 and the contact element 7, the first end section 7.1 is introduced into the end face 2.2 of the free end 2.1 of the electrical conductor 2. This is effected with such a high pressure and/or at such a high relative velocity that the first end section 7.1 of the contact element 7 and the electrical conductor 2 are connected to one another with a material bond at least in certain regions as a result of the high pressure and/or as a result of the high relative velocity.

[0155] The first end section 7.1 of the contact element 7 is preferably also introduced into the electrical conductor 2 in such a manner that the contact element 7 does not make contact with the outer circumference of the electrical conductor 2 if the first end section 7.1 is in its end position in the electrical conductor 2.

[0156] The end position is preferably an axial position in which the first end section 7.1 of the contact element 7 has completely penetrated the electrical conductor 2. However, it may also be an axial position in which the first end section 7.1 of the contact element 7 has not completely penetrated the electrical conductor 2 and a distance remains between the end face 2.2 of the free end 2.1 of the electrical conductor 2 and the middle section 7.2 of the contact element 7.

[0157] In particular, the free end 2.1 of the electrical conductor 2 is introduced into an end face 2.2 which is initially still completely closed and is penetrated only by the introduction of the first end section 7.1 of the contact element 7. Therefore, a hole in the end face 2.2 is not absolutely necessary. In principle, however, a hole, in particular a centering hole, can also be provided.

[0158] The first end section 7.1 of the contact element 7 can be introduced into the free end 2.1 of the electrical conductor 2 at a relative velocity of at least 5 m/s, preferably at least 10 m/s, particularly preferably at least 20 m/s, more preferably at least 30 m/s, and very particularly preferably at least 40 m/s.

[0159] In order to further improve the mechanical connection, in particular in order to optimize a connection with a material bond, a rotary movement of the contact element 7 can be superimposed on an axial movement in the axial direction, which extends along a longitudinal axis L of the electrical cable 1, when introducing the first end section 7.1 of the contact element 7 into the electrical conductor 2. The corresponding frictional energy can facilitate the production of a connection with a material bond.

[0160] In order to produce the connection arrangement 6, provision may be made of an apparatus 9 having means in order to introduce the first end section 7.1 of the contact element into the end face 2.2 of the free end 2.1 of the electrical conductor 2 with a material bond at least in certain regions at high velocity and/or with high mechanical force. An exemplary apparatus 9 indicated only schematically is illustrated in FIG. 13.

[0161] The means can be in the form of pneumatic, electromagnetic, pyrotechnic or gravitation-based means in order to sufficiently accelerate the contact element 7. Provision may also be made for a means driven by spring force to insert the first end section 7.1 of the contact element 7 into the end face 2.2 of the free end 2.1 of the electrical conductor 2. The means however are not limited to pneumatic, electromagnetic, pyrotechnic, gravitation-based, nor spring force, and other means are similarly contemplated so as to generate the desired result.

[0162] FIG. 13 illustrates, by way of example, an apparatus 9 having a pneumatic means which is in the form of a compressed air cannon 10 for inserting the contact element 7.

[0163] In order to facilitate the penetration of the contact element 7 or the front end section 7.1 of the contact element 7 into the end face 2.2 of the electrical conductor 2, different geometries of the first end section 7.1 can be provided.

[0164] In particular, provision may be made for the cross section of the first end section 7.1 to taper in the direction of the free end 7.3 of the first end section 7.1, in particular for the first end section 7.1 of the contact element 7 to be conically shaped. A corresponding configuration is illustrated in all exemplary embodiments in FIGS. 2 to 12. In particular, the exemplary embodiments shown in FIGS. 5 to 7 show different variants of an advantageous conical shape of the first end section.

[0165] The free end 7.3 of the first end section 7.1 of the contact element 7 may have, for example, a curvature 11 (cf., for example, FIG. 3) or a tip 12 (cf., for example, FIG. 4).

[0166] In particular, in order to facilitate a form-fitting connection, the first end section 7.1 of the contact element 7 may have at least one radial shoulder 13, preferably at least one radial cutting edge 14 and/or an undercut 15. The exemplary embodiments in FIGS. 8 to 11 show, by way of example, different variants with corresponding radial shoulders 13 which make it possible for the contact element 7 to hook into the electrical conductor 2. A tip 12 of the free end 7.3, as shown in the exemplary embodiment in FIG. 4, can also have a corresponding radial shoulder 13.

[0167] FIG. 11 shows an embodiment of the invention in which a radial cutting edge 14 with an undercut 15 is provided. FIG. 12 shows an enlarged section in a sectional illustration. A chip 16 of the electrical conductor 2 can be completely or partially abraded by means of the cutting edge 14. The chip 16 can then be conveyed into the undercut 15, thus making it possible to produce and optimize a form-fitting connection and/or a connection with a material bond.

[0168] Provision may also be made for the first end section 7.1 of the contact element 7 to have a coating, preferably a coating made of a material with a lower melting temperature than that of the material of the contact element 7 and that of the material of the electrical conductor 2. For example, it is possible to provide a silver coating which is applied to a contact element 7 formed from brass.

Operation

[0169] A first object of the present invention is a connection arrangement (6) comprising an electrical cable (1) and a contact element (7) connected to a free end (2.1) of an electrical conductor (2) of the electrical cable (1), wherein a first end section (7.1) of the contact element (7) penetrates an end face (2.2) of the free end (2.1) of the electrical conductor (2), characterized in that at least one region of the first end section (7.1) of the contact element (7) is directly connected to the electrical conductor (2) with a material bond.

[0170] A second object of the present invention is a connection arrangement (6) according to claim 1, characterized in that the contact element (7) is connected to the free end (2.1) of the electrical conductor (2) in such a manner that the contact element (7) does not make contact with an outer circumference of the electrical conductor (2).

[0171] A third object of the present invention is a connection arrangement (6) according to claim 1 or 2, characterized in that the electrical conductor (2) is in the form of an inner conductor of the cable (1) and the contact element (7) is in the form of an inner conductor contact element of a plug connector (5).

[0172] A fourth object of the present invention is a connection arrangement (6) according to one of claims 1 to 3, characterized in that the outer diameter of the contact element (7) corresponds to the outer diameter of the electrical conductor (2) in a middle section (7.2) adjoining the first end section (7.1) of the contact element (7).

[0173] A fifth object of the present invention is a connection arrangement (6) according to one of claims 1 to 4, characterized in that the connection between the first end section (7.1) of the contact element (7) and the free end (2.1) of the electrical conductor (2) is a cold-welded connection, preferably a gas-tight connection.

[0174] A sixth object of the present invention is a connection arrangement (6) according to one of claims 1 to 5, characterized in that the cross section of the first end section (7.1) tapers in the direction of the free end (2.1) of the first end section (7.1).

[0175] A seventh object of the present invention is a connection arrangement (6) according to one of claims 1 to 6, characterized in that the first end section (7.1) of the contact element (7) has at least one radial shoulder (13), preferably at least one radial cutting edge (14) and/or an undercut (15).

[0176] An eighth object of the present invention is a connection arrangement (6) according to one of claims 1 to 7, characterized in that the first end section (7.1) of the contact element (7) has a coating.

[0177] A ninth object of the present invention is a contact element (7) for connection to a free end (2.1) of an electrical conductor (2) of an electrical cable (1), having a contact body (7.4) with a first end section (7.1), wherein the first end section (7.1) is configured to penetrate an end face (2.2) of the free end (2.1) of the electrical conductor (2), characterized in that at least one section of the first end section (7.1) of the contact body (7.4) can be directly connected to the first conductor (2) with a material bond.

[0178] A tenth object of the present invention is an electrical plug connector (5) comprising a connection arrangement (6) according to one of claims 1 to 8.

[0179] An eleventh object of the present invention is a method for producing a connection between an electrical conductor (2) of an electrical cable (1) and a contact element (7), according to which a first end section (7.1) of the contact element (7) is introduced into an end face (2.2) of a free end (2.1) of the electrical conductor (2), characterized in that the first end section (7.1) of the contact element (7) is introduced into the free end (2.1) of the electrical conductor (2) with such a high pressure and/or at such a high relative velocity that the first end section (7.1) of the contact element (7) and the electrical conductor (2) are connected to one another with a material bond at least in certain regions as a result of the high pressure and/or the high relative velocity.

[0180] A twelfth object of the present invention is a method according to claim 11, characterized in that the high relative velocity is based on a high linear velocity and/or a high angular velocity.

[0181] A thirteenth object of the present invention is a method according to claim 11 or 12, characterized in that the contact element (7) is introduced into the free end (2.1) of the electrical conductor (2) in such a manner that the contact element (7) does not make contact with an outer circumference of the electrical conductor (2) if the first end section (7.1) is in its end position in the electrical conductor (2).

[0182] A fourteenth object of the present invention is a method according to one of claims 11 to 13, characterized in that the free end (2.1) of the electrical conductor (2) forms a completely closed end face (2.2) which is penetrated by introducing the first end section (7.1) of the contact element (7).

[0183] A fifteenth object of the present invention is an apparatus (9) for producing a connection arrangement (6) according to one of claims 1 to 8, characterized in that means (10) are provided for the purpose of introducing the first end section (7.1) of the contact element (7) into an end face (2.2) of the free end (2.1) of the electrical conductor (2) with a material bond at least in certain regions at high velocity and/or with high mechanical force.

[0184] A sixteenth object of the present invention is a connection arrangement (6) comprising an electrical cable (1) having an electrical conductor 2; a contact element (7) connected to a free end (2.1) of the electrical conductor (2) of the electrical cable (1), and wherein a first end section (7.1) of the contact element (7) penetrates an end face (2.2) of the free end (2.1) of the electrical conductor 2; and at least one region of the first end section (7.1) of the contact element (7) is directly connected to the electrical conductor (2) with a material bond.

[0185] A seventeenth object of the present invention is a connection arrangement (6) wherein the contact element (7) is connected to the free end (2.1) of the electrical conductor (2) in such a manner that the contact element (7) does not make contact with an outer circumference of the electrical conductor (2).

[0186] An eighteenth object of the present invention is a connection arrangement (6) wherein the electrical conductor (2) is in the form of an inner conductor of the cable, (1) and the contact element (7) is in the form of an inner conductor contact element of a plug connector (5).

[0187] A nineteenth object of the present invention is a connection arrangement (6) wherein an outer diameter of the contact element (7) corresponds to an outer diameter of the electrical conductor (2) in a middle section (7.2) adjoining the first end section (7.1) of the contact element (7).

[0188] A twentieth object of the present invention is a connection arrangement (6) wherein the connection between the first end section (7.1) of the contact element (7) and the free end (2.1) of the electrical conductor (2) is a cold-welded connection.

[0189] A twenty first object of the present invention is a connection arrangement (6) wherein a cross section of the first end section (7.1) tapers in the direction of the free end (2.1) of the first end section (7.1).

[0190] A twenty second object of the present invention is a connection arrangement (6) wherein the first end section (7.1) of the contact element (7) has at least one radial shoulder (13).

[0191] A twenty third object of the present invention is a connection arrangement (6) further comprising: a coating on the contact element (7).

[0192] A twenty fourth object of the present invention is a contact element (7) for connection to a free end (2.1) of an electrical conductor (2) of an electrical cable comprising: the contact element (1), having a contact body (7.4) with a first end section (7.1), and wherein the first end section (7.1) is configured to penetrate an end face (2.2) of the free end (2.1) of the electrical conductor (2); and wherein at least one section of the first end section (7.1) of the contact body (7.4) is directly connected to the first conductor (2) with a material bond.

[0193] A twenty fifth object of the present invention is a method for producing a connection between an electrical conductor (2) of an electrical cable (1) and a contact element (7), the method comprising the steps: providing a contact element having a first end section; introducing the first end section (7.1) of the contact element (7) into an end face (2.2) of a free end (2.1) of the electrical conductor (2); and introducing the first end section (7.1) of the contact element (7) into the free end (2.1) of the electrical conductor (2) with high pressure and high relative velocity so that the first end section (7.1) of the contact element (7) and the electrical conductor (2) are connected to one another with a material bond, at least in certain regions, as a result of the high pressure and the high relative velocity.

[0194] A twenty sixth object of the present invention is a method wherein the high relative velocity is based on a high linear velocity and/or a high angular velocity.

[0195] A twenty seventh object of the present invention is a method wherein the contact element (7) is introduced into the free end (2.1) of the electrical conductor (2) in such a manner that the contact element (7) does not make contact with an outer circumference of the electrical conductor (2) when the first end section (7.1) is in position in the electrical conductor (2).

[0196] A twenty eighth object of the present invention is a method and wherein the free end (2.1) of the electrical conductor (2) forms a completely closed end face (2.2) that is penetrated by introducing the first end section (7.1) of the contact element (7).

[0197] A twenty ninth object of the present invention is a method further comprising: the steps of introducing the first end section (7.1) of the contact element (7) into an end face (2.2) of the free end (2.1) of the electrical conductor (2) with a material bond, at least in certain regions, at high velocity and/or with high mechanical force.

[0198] A thirtieth object of the present invention is a connection arrangement wherein the connection between the first end section (7.1) of the contact element (7) and the free end (2.1) of the electrical conductor (2) is a gas-tight connection.

[0199] A thirty first object of the present invention is a connection arrangement (6) wherein the first end section (7.1) of the contact element (7) has at least one radial cutting edge (14).

[0200] A thirty second object of the present invention is a connection arrangement (6) wherein the first end section (7.1) of the contact element (7) has at least one radial shoulder (13) and an undercut (15).

[0201] A thirty third object of the present invention is a method wherein the material bond created by introducing the first end section (7.1) of the contact element (7) into an end face (2.2) of the free end (2.1) of the electrical conductor (2) is accomplished with high mechanical force.

[0202] A thirty fourth object of the present invention is a method and wherein the material bond created by introducing the first end section (7.1) of the contact element (7) into an end face (2.2) of the free end (2.1) of the electrical conductor (2) is accomplished with high velocity and high mechanical force.