Abstract
The invention relates to a press-in contact, a component assembly comprising at least one contact receptacle and a press-in contact, and a method for manufacturing a press-in contact, The method comprising producing a rough contour, in particular a punched contour, of a press-in contact, with a connecting body and two limbs which adjoin the latter and are arranged opposite each other, wherein the limbs have press-in regions and end regions which face away from the connecting body and have contact portions which face each other and are spaced apart from each other in a defined manner, and reshaping the limbs, comprising moving the end regions of the limbs toward each other by at least partial plastic deformation of at least one of the limbs, wherein the contact portions of the limbs touch in a defined manner at least in sections after being relieved of load.
Claims
1. A component assembly comprising at least one contact receptacle and at least one plug-type contact for producing an electric connection, with a flat connecting body and two curved limbs having two flat sides adjoining the connecting body, wherein the connecting body and the limbs are configured as a single flat piece, wherein each limb has a press-in region and an end region with a contact portion, wherein the two limbs define a substantially almond-shaped inner contour, and wherein the contact portions of the two limbs face each other and touch in a defined manner at least in sections, wherein the plug-type contact is received in the contact receptacle by being prestressed; wherein the limbs have an attachment region for attachment to the flat connecting body, wherein the limbs have a concave constriction at a transition between the press-in region and the attachment region, said constriction being formed by curved portions of the limbs, wherein end regions of the limbs which face the connecting body furthermore have an inner rounding which merges into an inner space defined between the limbs, and wherein the concave constriction of the limbs defines a narrow point between the inner space and the inner rounding, wherein the curved portions of the limbs are configured to touch each other at the narrow point when received in the contact receptacle, and wherein the inner space is larger than the inner rounding.
2. A press-in contact, in particular punched press-in contact for producing an electric connection, with a flat connecting body and two curved limbs having two flat sides adjoining the connecting body, wherein the connecting body and the limbs are configured as a single flat piece, wherein each limb has a press-in region and an end region with a contact portion, wherein the two limbs define a substantially almond-shaped inner contour, and wherein the contact portions of the two limbs face each other and touch in a defined manner at least in sections, wherein the limbs have an attachment region for attachment to the connecting body, wherein the limbs have a concave constriction at a transition between the press-in region and the attachment region, said constriction being formed by curved portions of the limbs, wherein end regions of the limbs which face the connecting body furthermore have an inner rounding which merges into an inner space defined between the limbs, and wherein the concave constriction of the limbs defines a narrow point between the inner space and the inner rounding, wherein the curved portions of the limbs are configured to touch each other at the narrow point when received in the contact receptacle, and wherein the inner space is larger than the inner rounding.
3. The plug-type contact as claimed in claim 2, wherein the plug-type contact is defined as a press-in contact, in particular as a punched press-in contact.
4. The plug-type contact as claimed in claim 2, wherein the contact portions of the two limbs are prestressed against each other with a contact force.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) Further features and advantages of the invention emerge from the description below of a plurality of preferred exemplary embodiments with reference to the drawings, in which:
(2) FIG. 1a shows a rough contour of a press-in contact with two opposite limbs, in a schematically illustrated top view;
(3) FIG. 1b shows a schematically illustrated front view of the rough contour of the press-in contact according to FIG. 1a;
(4) FIG. 2a shows a schematically illustrated top view of a press-in contact which has been shaped by stamping and is based on the rough contour shown in FIG. 1a;
(5) FIG. 2b shows a schematically illustrated front view of the press-in contact shaped by stamping according to FIG. 2a;
(6) FIG. 3a shows a schematically illustrated top view of a press-in contact according to FIG. 2a in a reshaped state in which limbs of the press-in contact touch in sections;
(7) FIG. 3b shows a schematically illustrated front view of the press-in contact according to FIG. 3a;
(8) FIG. 4a shows a schematically illustrated top view of a rough contour of a further press-in contact with two opposite limbs;
(9) FIG. 4b shows a schematically illustrated front view of the rough contour of the press-in contact according to FIG. 4a;
(10) FIG. 5a shows a schematically illustrated top view of a press-in contact in accordance with the rough contour shown in FIG. 4a, in a state shaped by stamping;
(11) FIG. 5b shows a schematically illustrated front view of the press-in contact according to FIG. 5a;
(12) FIG. 6a shows a schematically illustrated top view of a press-in contact according to FIG. 5a with laterally disengaged limbs;
(13) FIG. 6b shows a schematically illustrated front view of the press-in contact according to FIG. 6a;
(14) FIG. 7a shows a schematically illustrated top view of a press-in contact according to FIG. 6a with limbs deformed in a longitudinal direction;
(15) FIG. 7b shows a schematically illustrated front view of the press-in contact according to FIG. 7a;
(16) FIG. 8a shows a schematically illustrated top view of a press-in contact according to FIG. 7a with limbs which are returned into a lateral neutral position and touch each other at least in sections;
(17) FIG. 8b shows a schematically illustrated front view of the press-in contact according to FIG. 8a;
(18) FIG. 9 shows a schematically illustrated illustration of a sequence of lateral positions of the limbs of a press-in contact according to FIGS. 4a to 8b;
(19) FIG. 10a shows a schematically illustrated top view of a further press-in contact with two limbs which touch at least in sections;
(20) FIG. 10b shows a schematically illustrated front view of the press-in contact according to FIG. 10a;
(21) FIG. 11 shows a simplified schematic view of a busbar with a plurality of press-in contacts;
(22) FIG. 12 shows a view of a detail of an excerpt of the illustration shown in FIG. 11;
(23) FIG. 13 shows a perspective view of a printed circuit board element with a plurality of contact receptacles for press-in contacts;
(24) FIG. 14a shows a schematically illustrated top view of a further embodiment of a press-in contact in a reshaped state;
(25) FIG. 14b shows a schematically illustrated front view of the press-in contact according to FIG. 14a; and
(26) FIG. 15 shows a schematically highly simplified sequence diagram of a method for manufacturing press-in contacts.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
(27) Various states of a press-in contact 100 according to an exemplary embodiment are illustrated during the manufacturing process with reference to FIGS. 1a to 3b.
(28) By way of example, the press-in contact 100 can be associated with a contact component, for example a busbar, compare FIG. 11. In particular, a plurality of press-in contacts 100 can be provided on a contact component. It therefore goes without saying that in particular the embodiments illustrated in FIGS. 1a to 10b can have or contain merely partial illustrations.
(29) FIGS. 1a and 1 b illustrate a rough contour of the press-in contact 100. The rough contour can be in particular a punched contour or cut contour which is produced from a substantially flat semi-finished product. The press-in contact 100 has a connecting body 1 from which two limbs or limb elements 21, 22 extend. The connecting body 1 and the limbs 21, 22 are preferably formed as a single piece and in particular are connected integrally to a component. The connecting contour to this component is provided by the connecting body 1. The limbs 21, 22 are configured substantially mirror-symmetrically. The limbs 21, 22 have an elongate extent and are oriented approximately in a U-shaped or V-shaped manner with respect to each other. Between their ends which merge into the connecting body 1, the limbs 21, 22 include a transition 7 which, for example, can also be referred to as a gusset. The transition 7 can be configured in particular as a rounding or chamfer 7. The attachment between the limbs 21, 22 and the connecting body 1 takes place substantially in an attachment region 6.
(30) The press-in contact 100 is preferably formed from a metallic conductive material. In particular, a plate-shaped or strip-shaped semifinished product which is substantially formed as flat material is involved. It is preferred if the press-in contact 100 is formed from a punchable or cuttable material. For example, it can be a material of the thickness d, also compare FIG. 1b. The connecting body 1 and the limbs 21, 22 can therefore have substantially the same thickness d. The limbs 21, 22 can furthermore have a width b. Along their longitudinal extent, the limb elements 21, 22 according to the rough shape illustrated in FIG. 1a can have substantially rectangular cross sections. In principle, it is conceivable also to design the limbs 21, 22 with substantially square cross sections. However, in particular because of the punching operation or cutting operation, changes in shape can also be produced in the limbs 21, 22, and therefore cross sections differing from the rectangular shape are also conceivable.
(31) The intermediate state, illustrated in FIGS. 2a and 2b, of a press-in contact 100 differs from the rough state, shown in FIGS. 1a and 1 b, of the press-in contact 100 essentially in that smoothing and/or rounding of at least some of the edges of the rough contour have/has taken place. Such an operation can be realized in particular by means of stamping. The stamping can be combined with a punching and/or cutting operation. The smoothing and/or rounding of edges, in particular of cut edges or punched edges, can contribute to avoiding stress concentrations which may arise under some circumstances during subsequent reshaping operations and/or during the joining of the press-in contact 100. Furthermore, for example, the risk of injuries during the manual handling of the press-in contact 100 can be reduced.
(32) Each of the limbs 21, 22 furthermore has an end region 4 which faces away from the connecting body 1. Contact portions 42, 44 can be provided in the end region 4 of the limbs 21, 22. The limb 21 can be the contact portion 42. The limb 22 can be the contact portion 44. In the manufacturing stage illustrated in FIGS. 2a and 2b, the contact portions 42, 44 of the limbs 21, 22 are significantly spaced apart from each other. A minimum distance between the contact portions 42, 44 can be defined, for example, by a minimum wall thickness of a punching tool or cutting tool with which the rough contour of the press-in contact 100 is produced. According to the basic configuration shown in FIGS. 1a and 1 b, the limbs 21, 22 define therebetween an intermediate space 10, which, however, is not surrounded by a closed contour since there is (initially) no touching between the contact portions 42, 44.
(33) FIGS. 3a and 3b illustrate a further manufacturing stage in which the limbs 21, 22 are moved toward each other in such a manner that the contact portions 42, 44 (compare FIG. 2a) touch at least in sections. In this manner, the limbs 21, 22 can together form a point 3 which is closed. In other words, the closed point 3 does not have a gap or a spacing. In order to produce the contact connection, the contact portions 42, 44, or at least one of the contact portions 42, 44, can be moved toward each other in a longitudinal direction, compare arrows denoted by 46, 48 in FIG. 2b. By producing a plastic deformation at least in the case of one of the limbs 21, 22, the state, shown in FIG. 3a, of the press-in contact 100 can be kept stable.
(34) By closing the limbs 21, 22, the intermediate space 10 can be converted into an inner contour or an inner space 9 which now has a closed boundary. In general, the inner space 9 has an elongate extent and is configured to be substantially oval or elliptical or in the form of a gusset or spherical lune. The inner space 9 can be provided with the rounding 7 in particular at the end thereof facing the connecting body 1 and with a point 8 at the end thereof facing away from the connecting body 1. Overall, the inner space 9 can be configured in an almond-shaped manner. The limbs 21, 22 can each have a press-in region 5 between the end regions 4 thereof and the attachment regions 6. According to the view shown in FIG. 3a, the press-in region 5 of each limb 21, 22 can be arched convexly outward. In the closed state of the limbs 21, 22, it is possible in the press-in regions 5 overall to produce a limb dimension or a width B, compare FIG. 3b. The limb dimension B has to be adapted in a particular manner to a size of a contact receptacle in order to be able to provide a secure press-in connection. It would therefore be advantageous to be able to manufacture the limb dimension B with a high degree of reproducibility and tolerances which are as small as possible. By the limbs 21, 22 being reshaped in such a manner that their end regions 42, 44 at least partially touch, the limb dimension B can be defined in a highly precise manner. Nevertheless, various advantages which arise by means of the configuration of the press-in contact 100 as a press-in contact with separate limbs 21, 22 can be maintained.
(35) A further advantageous embodiment of the method and a press-in contact 100a produced in the process are illustrated with reference to FIGS. 4a to 8b.
(36) FIGS. 4a, 4b, 5a and 5b may substantially correspond to FIGS. 1a, 1 b, 2a and 2b. FIGS. 4a and 4b show a press-in contact 100a in the rough state, i.e., for example, as a punched rough part. The press-in contact 100a has in a known manner a connecting body 1 and two limbs 21, 22 adjoining the latter. The limbs 21, 22 have a substantially V-shaped or U-shaped arrangement. The press-in contact 100a can be punched by way of example from a semi-finished product of thickness d (compare FIG. 4b).
(37) FIGS. 5a and 5b illustrate a press-in contact 100a which is based on the press-in contact 100a according to FIG. 4a and furthermore has rounded or smoothed edges and burrs. The roundings or smoothings of the press-in contact 100a can be produced in particular by means of stamping. In a known manner, the limbs 21, 22 can define an (open) intermediate space 10 therebetween. FIGS. 6a and 6b illustrate a deformation step in which the limbs 21, 22 of a press-in contact 100a are deflected laterally. The deflected limbs are denoted by 21 and 22 in FIG. 6b. The lateral deflection can take place in the direction of arrows denoted by 50 and 52 in FIG. 6b. The lateral deflection can be limited essentially to contact portions 42, 44 of the limbs 21, 22.
(38) In other words, at most only an extremely small lateral deflection can take place, for example, in the attachment region 6 of the limbs 21, 22. The arrows 50, 52 in FIG. 6b illustrate by way of example a (lateral) direction which is oriented substantially perpendicularly to a central plane or neutral plane through the press-in contact 100a. It is preferred if the limbs 21, 22 are deflected laterally to such an extent that at least the contact portions 42, 44 are completely offset laterally with respect to each other. This state is shown in FIG. 6b. The lateral deflection can in principle take place purely elastically. However, it is also conceivable to at least partially also plastically deform the limbs 21, 22 during the lateral deflection.
(39) Based on the position shown in FIG. 6b, the limbs 21, 22 can advantageously be deformed toward each other in a particular manner in order to permit a state in which the contact portions 42, 44 at least partially make contact with each other, with a prestress being formed. Such an operation is illustrated by FIGS. 7a and 7b. FIG. 7b shows that the limbs 21, 22 can be moved toward each other from the position shown in FIG. 6b. Said movement (also: longitudinal movement) is illustrated in FIG. 7b by arrows denoted by 46, 48. It is furthermore apparent from FIG. 7b that the limbs 21, 22 can not only be moved toward each other but even at least partially past each other at least in the region of the contact portions 42, 44 thereof. Even if, according to the illustration of a press-in contact 100a that is shown in FIG. 7a, there is apparently contact between the contact portions 42, 44, a relative movement of the limbs 21, 22 beyond this state is made possible.
(40) This is particularly advantageous since a plastic deformation of the limbs 21, 22 can thereby be produced, said deformation then being able to provide a prestressing force when the limbs 21, 22 are returned again into the neutral position thereof. In other words, the movement of the limbs 21, 22 is not limited by a stop which would be provided by the contact of the contact portions 42, 44 if the contact portions 42, 44 do not overlap laterally. The limbs 21, 22 can therefore be overstretched in the longitudinal direction (arrows 46, 58). If the limbs 21, 22 should then be relieved of load, it would be conceivable for said limbs to remain in a mutually at least partially overlapping position in the laterally disengaged state.
(41) FIGS. 8a and 8b illustrate a state of a press-in contact 100a that is based on the state according to FIGS. 7a and 7b, but wherein the limbs and in particular the contact portions 42, 44 therefore are returned into the (lateral) neutral position thereof, compare reference signs 21, 22 in FIG. 8b. This can secondly take place using a (lateral) elastic resetting force of the limbs 21, 22. However, should a plastic deformation of the limbs 21, 22 occur in the lateral direction, for example, in the event of the lateral disengagement illustrated in FIGS. 6a and 6b, an oppositely directed plastic deformation can bring about the neutral state of the limbs 21, 22 that is shown in FIG. 8b. Nevertheless, the contact portions 42, 44 can come into contact with each other in a defined manner with a prestressing force F being formed. The prestressing force F can be defined in particular by targeted overstretching of the limbs 21, 22, also compare FIG. 7b. Analogously to the state shown in FIG. 3a, in the case of the press-in contact 100a it is possible to produce a press-in region 5 which, owing to the defined contact between the contact portions 42, 44, leads to a limb dimension B (compare FIG. 8b) which has small tolerances and can be reproduced highly precisely.
(42) In particular, the lateral disengaging step illustrated in FIGS. 6a and 6b permits a significant deformation of the limbs 21, 22 of the press-in contact 100a. Inherent stresses in the material of the press-in contact 100a can therefore be produced in a specific manner and used in order to improve the dimensional stability and functional reliability thereof. It goes without saying that in particular the steps, shown in FIGS. 6a to 7b, of the lateral disengagement and of the limbs 21, 22 moving toward each other can take place as a consequence of a combined movement. The steps can in principle be executed simultaneously, but furthermore also in a manner offset in terms of time. As already explained above, it is preferred if the two limbs 21, 22 are deflected and reshaped in a symmetrical manner. In principle, however, it is also conceivable to move and to deform just one of the two limbs 21, 22 in a corresponding manner.
(43) FIG. 9 shows, merely for illustrative purposes, a superimposition of various states of the press-in contact 100a that approximately correspond to the positions shown in FIGS. 5b to 8b. A lateral neutral plane or plane of symmetry of the press-in contact 100a or of the semi-finished product used for the manufacturing thereof is indicated at 60. FIG. 9 illustrates the press-in contact 100a in slightly tilted form in order to make both of the limbs 21, 22 visible even in the neutral position despite a symmetrical configuration of the limbs 21, 22.
(44) In the punched and optionally stamped state, the limbs 21, 22 are in the neutral position thereof (laterally). In a further step which is also illustrated with reference to FIGS. 6a and 6b, a lateral disengagement of the limbs takes place, compare reference signs 21, 22, in the direction of the arrows denoted by 50 and 52. In said disengaged state, the limbs can be deformed relative to each other in the longitudinal direction, compare the reference signs 21, 22. According to the orientation shown in FIG. 9, this can take place approximately substantially perpendicularly to the viewing plane there. In this manner, a plastic deformation of the limbs 21, 22 can take place, said plastic deformation being usable in order to produce a prestress. The limbs can subsequently be transferred again into the neutral position thereof with respect to the neutral plane 60, compare reference signs 21 and 22. This can take place along arrows denoted 50, 52. The return of the limbs 21, 22 can basically take place using the inherent elasticity thereof. Alternatively or additionally, it is, however, also conceivable for the limbs 21, 22 also to be returned by plastic deformation.
(45) A further advantageous embodiment of a press-in contact 100b is illustrated with reference to FIGS. 10a and 10b. In a known manner, the press-in contact 100b has a connecting region 1 and two limbs 21, 22 which adjoin the latter and are configured substantially symmetrically to each other. The limbs 21, 22 are attached to the connecting body 1 in an attachment region 6. The limbs 21, 22, on their end region 4 facing away from the connecting body 1, have contact portions 42, 44 which at least partially touch each other, in particular with a prestressing force being formed. In this manner, the contact portions 42, 44 of the limbs 21, 22 can form a closed point 3. In order to produce the configuration shown in FIG. 10a, use can be made, for example, of the method illustrated according to FIGS. 4a to 8b.
(46) Between the end region 4 and the attachment region 6, the limbs 21, 22 can define a press-in region 5, in which a limb dimension B is produced, also compare FIG. 10b. An inner contour or a (closed) inner space 9 of approximately almond-shaped design can be produced between the limbs 21, 22. In the direction of the connecting body 1, the inner space 9 can have a rounded end or a chamfer 7. In the direction of the point 3, the inner space 9 can have a tapering end 8.
(47) In contrast to the previously described press-in contacts 100 and 100a, the press-in contact 100b has a substantially continuously curved configuration of the limbs 21, 22. In particular, the limbs 21, 22 of the press-in contact 100b are embodied substantially without rectilinear portions in the longitudinal extent thereof. For example, in the case of the limb 22, a limb radius is indicated that is denoted by R and extends over substantial regions of the limb 22, at least over the press-in region 5. A targeted adaptation of the limb radius R permits an optimization of a plug-in force or joining force during the installation of the press-in contact 100b and optimization of the contact surface of the press-in contact 100b upon contact with a contact receptacle, for example a receiving bushing. It is of advantage here if a back of the press-in contact 100b bears in as planar a manner as possible against a corresponding contact receptacle.
(48) Furthermore, the limb 22 has an inner transition radius which is denoted by r and describes a transition between the press-in region 5 and the end region 4, in particular the contact portion 44 thereof. A suitable configuration of the transition radius r permits a targeted deformation of the limbs 21, 22 of the press-in contact 100b during the insertion into a contact receptacle. In particular, the transition radii r of the two limbs 21, 22 can nestle against each other when the press-in region 5 of the limbs 21, 22 is pressed together during the joining. Therefore, in the case of the press-in contact 100b according to FIG. 10a, an inner space 9 can be produced, the rounding 7 of which, which faces the connecting body 1, merges into a concave rounding which extends substantially over at least the press-in region 5, wherein the convex transition radius r adjoins the latter and tapers in the direction of the point 3 of the press-in body 100b.
(49) The previously described press-in contacts 100, 100a and 100b can be used, for example, in vehicle manufacturing or in similar use areas in which high currents flow. Customary dimensions for the thickness d of the semi-finished product (compare FIG. 1b) can be approximately within the range of a few tenths of a millimeter up to several millimeters. A limb dimension B of approximately 2.5d to 4d can be produced. The limbs 21, 22 can have a width b perpendicular to the thickness d of similar orders of magnitude as the thickness d. In principle, the limbs 21, 22 can have a square cross section. However, it is also conceivable for the thickness d to be greater than the width b. Conversely, it is conceivable for the thickness d to be smaller than the width b. It is preferred if the lateral deflection of the limbs 21, 22 brings about an offset which is greater than or equal to the thickness d at least in the region of the contact portions 42, 44. In particular if the offset is greater than the thickness d, the limbs 21, 22 can be guided past each other.
(50) However, it goes without saying that configurations of the press-in contacts 100, 100a, 100b and of the press-in contact 100c, which is illustrated below with reference to FIGS. 14a and 14b, which differ from the above-described dimensions are also conceivable.
(51) FIGS. 11 and 12 illustrate by way of example a busbar 302 which is representative of a multiplicity of conceivable contact components. The busbar 302 has by way of example five contact elements 100, of which one is illustrated enlarged in sections in FIG. 12, compare detail X. By means of a plurality of press-in contacts 100, a parallel contact connection can take place to a certain extent in order to be able to transmit particularly high currents. In this manner, for example, several hundred amperes can be transmitted. It is preferred if the busbar 302 shown in FIG. 11 and all of the press-in contacts 100 accommodated thereon are configured as a single piece.
(52) FIG. 13 illustrates a printed circuit board element 301 which has a plurality of contact receptacles 304, in particular receiving bushings. The contact elements 304 can customarily be bores or similar design elements. The contact receptacles 304 can be metalized and/or can have metallic inserts. The printed circuit board element 301 can be matched to the busbar 302 and can provide, for example, five corresponding contact receptacles 304 in order, in a joined state, to be able to accommodate the five press-in contacts 100 of the busbar 302.
(53) A further advantageous embodiment of the method and a press-in contact 100c produced in the process are illustrated with reference to FIGS. 14a and 14b. The press-in contact 100c can be basically produced analogously to the press-in contacts 100, 100a, 100b using the above-described manufacturing steps. In particular, the limbs 21, 22 of the press-in contact 100c can be prestressed in the above-described manner in order, after a reshaping operation, to touch in a defined manner at least in sections in the region of the contact portions 42, 44 thereof.
(54) The press-in contact 100c is distinguished in particular in respect of the configuration of the transition between the press-in region 5 and the attachment region 6 by a modified configuration of the limbs 21, 22. The limbs can be provided with a constriction 68, which is formed by curved portions 70, 72, between the rounding 7 associated with the connecting body 1 and the inner space or the inner contour 9. A curved portion 70 is provided in the case of the limb 21. A curved portion 72 is provided in the case of the limb 22. The curved portions 70, 72 can be configured to be substantially convex on the mutually facing sides thereof and substantially concave on the sides thereof which face away from each other. An arrow denoted by R indicates in FIG. 14a a concave curvature of the portion 72 in the case of the limb 22. Each of the limbs 21, 22 can thus have an S-shaped configuration. Accordingly, the transition between the inner space 9 and the rounding 7 of the press-in contact 100c can comprise a narrow point.
(55) This contour of the press-in contact 100c can be produced in particular as a rough contour, for example by punching a corresponding blank. A rough contour with limbs 21, 22 forming a constriction 68 may be of advantage in the reshaping step. Mutually facing inner surfaces of the portions 70, 72 in the region of the narrow point can come into contact with each other during the reshaping step. A favorable force profile can thereby be produced during the reshaping of the limbs 21, 22. This configuration can also be of advantage after the reshaping of the limbs 21, 22. When the press-in contact 100c is pressed into a contact receptacle 304 (cf. FIG. 13) the mutually facing inner surfaces of the portions 70, 72 can enter into contact with each other. The stresses produced in the press-in contact 100c during the pressing-in operation can thereby be defined even more precisely. Furthermore, the configuration of the press-in contact 100c illustrated with reference to FIGS. 14a and 14b can contribute to further reducing stresses in the attachment region 6, at which the limbs 21, 22 merge into the connecting body 1.
(56) FIG. 15 shows, in a simplified manner, a schematic sequence diagram of a method for manufacturing a press-in contact. The method can start at a step S10. This is followed by a step S12 in which a rough shape or rough contour of a press-in contact is produced. This can take place in particular by means of a separating method. A non-cutting separating method is preferably involved here. For example, the rough contour can be produced by means of punching, cutting or precise cutting. The rough contour of the press-in contact preferably comprises a connecting body and two limb elements or limbs extending from the latter. In particular, the limbs can be formed substantially symmetrically to each other and can substantially extend in the longitudinal direction for example as limbs of a V or U. It is preferred if the limbs have contact portions in the end regions thereof facing away from the connecting body, but said contact portions do not touch in the rough contour.
(57) This can be followed by a step S14 in which edges of the rough contour of the press-in contact are smoothed or rounded. However, in principle, step S14 can also be passed over. According to some configurations, step S14 can be combined with step S12. For example, it is conceivable to produce and to smooth the rough contour of the press-in contact by means of a combined punching/stamping operation. Burrs and/or punched edges can be deburred by means of stamping.
(58) This is followed by step S16 which involves reshaping the press-in contact. The limbs of the press-in contact, in particular the contact portions thereof, are advantageously plastically preshaped here in such a manner that there is at least partial touching between the contact portions of the limbs after the reshaping operation. This can contribute in a particular manner to improving the dimensional stability of the press-in contact.
(59) According to various embodiment embodiments, the reshaping step S16 can comprise various partial steps. For example, a step S18 can be provided in which at least one limb, preferably both limbs, is/are deflected laterally. Said step can relate in particular to the contact portions of the limbs. This can be followed by a step S20 in which the limbs, in particular the contact portions thereof, are moved toward each other. The contact portions of the limbs are preferably laterally disengaged here in such a manner that said contact portions can be at least partially moved past each other. In this manner, the limbs can be plastically deformed in a particular manner. This can be followed by a further step S22 in which the (laterally deflected) limbs are returned laterally into the starting position or neutral position thereof. Since, however, at least one of the limbs, preferably both limbs, has/have been plastically deformed in the direction toward each other, after the limbs are returned, there can be touching at least in sections between the contact portions. The limbs have preferably been deformed in such a manner that the touching takes place with the production of a prestress. The touching between the contact portions can thereby be reproduced particularly securely and readily in terms of process engineering. This can be followed by a step S24 which terminates the method.
(60) It goes without saying that the method can be used in order simultaneously to manufacture a plurality of press-in contacts which, for example, are formed as a single piece with a suitable carrier component, for example a busbar. Overall, it is possible with the method to manufacture press-in contacts which are suitable for transmitting large currents and which can be fitted simply and reliably. The design of the press-in contacts with two limbs, the contact portions of which basically are not rigidly connected to each other, but touch each other in a defined manner, affords various advantages.
(61) A press-in contact according to one of the abovementioned aspects is suitable both for permanent press-in connections which are not designed as releasable plug-type connections, and also for releasable plug-type connections. Releasable plug-type connections can be produced and separated repeatedly. Accordingly, the press-in contact, at least according to some embodiment embodiments, can generally also be a plug-type contact.
