CONNECTING ELEMENT FOR MOUNTING AN ELECTRICAL CIRCUIT BOARD TO A FLAT ELECTRICAL CONDUCTOR

Abstract

A connecting element for mounting an electrical circuit board to an electrical flat conductor, in particular a busbar, has a flat or substantially flat mounting surface for applying and mounting the connecting element to the circuit board, and a tulip contact for receiving the flat conductor in an electrically contacting manner. The tulip contact includes at least one clamping element and a support element, between which a receptacle for the flat conductor is provided, and wherein the tulip contact preferably extends at a mounting angle greater than 45° and less than 135° with respect to the mounting surface. An electrical circuit board having such a contact element, a terminal block having such an electrical circuit board, and a method for automated mounting of such a terminal block are also provided.

Claims

1. A connecting element, comprising (a) a flat mounting portion configured for mounting on a circuit board; and (b) a tulip contact configured to receive a flat conductor in an electrically contacting manner and including at least one clamping element and a support element between which a receptacle for the flat conductor is defined.

2. A connecting element as defined in claim 1, wherein said tulip contact tulip extends at a mounting angle greater than 45° and less than 135° relative to said mounting portion.

3. A connecting element as defined in claim 1, wherein said clamping element includes a latch which clamps onto the flat conductor.

4. A connecting element as defined in claim 2, wherein said support element extends from said mounting portion towards a free end at the mounting angle.

5. A connecting element as defined in claim 2, wherein a free end of said clamping element extends from said mounting portion at the mounting angle.

6. A connecting element as defined in 1, and further comprising a connecting arm extending from said mounting portion opposite said support element, said connecting arm extending above and spaced from a free end of said support element, said at least one clamping element extending from said connecting arm.

7. A connecting element as defined in claim 6, wherein said at least one clamping element is extends resiliently from said connecting arm.

8. A connecting element as defined in claim 1, wherein said at least one clamping element extends in a sliding direction relative to the flat conductor and said support element extends against the sliding direction.

9. A connecting element as defined in claim 6, wherein at least two clamping elements are arranged side by side on said connecting arm.

10. A connecting element as defined in claim 6, wherein said connecting arm has a rectangular cross-sectional shape.

11. A connecting element as defined in claim 6, wherein an outer surface of said connecting arm is configured for fastening to an automation robot.

12. A connecting element as defined in claim 1, wherein said mounting portion contains a through-hole for mounting on the circuit board.

13. A connecting element as defined in claim 1, wherein said mounting portion, said connecting arm and said at least one clamping element are manufactured from an electrically conductive flat strip material as a stamped and bent component.

14. An electrical circuit board including at least one connecting element as defined in claim 1.

15. An electrical circuit board as defined in claim 14, wherein said mounting portion of each connecting element lies flat against the circuit board.

16. A terminal block, comprising (a) a stackable housing containing at least one connection device for an electrical conductor; (b) a busbar; (c) at least one electrical circuit board; and (d) at least one connecting element mounted on said circuit board and electrically connected with said busbar.

17. A terminal block as defined in claim 16, wherein said housing includes at least one pin and said circuit board contains at least one through-hole which receives said pin to prevent a relative movement between said circuit board and said housing during mounting of the connecting element to the busbar.

18. A terminal block as defined in claim 16, wherein said housing comprises a first housing shell containing a recess for receiving a first circuit board and a second housing shell containing a recess for receiving a second circuit board.

19. A terminal block as defined in claim 18, and further comprising an insulating wall arranged between said housing shells.

20. A method for automated manufacture of a terminal block comprising the steps of (a) mounting a first flat conductor in a housing of the terminal block; (b) sliding a circuit board having with a connecting element onto the flat conductor in a recess of the housing.

21. The method as defined in claim 20, wherein the connecting element (1) is clamped to the flat conductor when the circuit board is mounted and also establishes an electrically conductive contact with the flat conductor in the mounted state.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0032] Other objects and advantages of the invention will become apparent from a study of the following description when viewed in the light of the accompanying drawing, in which:

[0033] FIG. 1 is a perspective view of a section of a terminal block with a circuit board to which a connecting element is attached;

[0034] FIGS. 2A, 2B, and 2C are perspective views of different sections, respectively, of a terminal block with a circuit board to which a connecting element of a further embodiment is attached;

[0035] FIG. 2D is a perspective view of a housing shell of a terminal block;

[0036] FIG. 2E is a perspective view of a circuit board with a plurality of connection elements;

[0037] FIG. 2F is a perspective view of the housing shell of FIG. 2D with the circuit board of FIG. 2E mounted thereon;

[0038] FIG. 3A is a perspective view of a first housing shell of a double-shell terminal block with a mounted circuit board;

[0039] FIG. 3B is a perspective view of a second housing shell of a double-shell terminal block with a mounted circuit board;

[0040] FIG. 3C is an exploded view of the housing shells of FIGS. 3A and 3B with an insulating wall therebetween;

[0041] FIG. 3D is a perspective view of the mounted double-shell terminal block;

[0042] FIG. 4A is a perspective view of a section of a double-shell terminal block; and

[0043] FIG. 4B is a perspective view of a section of a housing shell of a further embodiment of a terminal block.

DETAILED DESCRIPTION

[0044] FIG. 1 shows a section of a terminal block 4, having a circuit board to which a connecting element 1 is attached, which is provided for mounting the electrical circuit board 3 to a flat electrical conductor 2. The connecting element 1 is manufactured in one piece as a stamped and bent component. It is made of a material with good electrical conductivity. The flat conductor 2 can be, for example, a busbar also made of a material with good conductivity. In the following, the terms flat conductor 2 and busbar are therefore used synonymously.

[0045] For mounting the connecting element 1 on the electrical circuit board 3, the connecting element 1 has a flat mounting surface 13. The mounting surface 13 is provided for flat contact with the circuit board 3. In order to fasten the connecting element 1 to the mounting surface 13, the connecting element 1 has a mounting device 131 in the form of a through-hole. This allows the connecting element 1 to be fastened to the circuit board 3, for example, by soldering and/or, optionally, by riveting or screwing. In addition, the connecting element 1 is soldered onto a conductor track (not shown) of the circuit board 3 so that it is electrically conductively connected to the conductor track of the circuit board 3.

[0046] Alternatively, the contact element could also be used in such a way that the busbar and circuit board are arranged in parallel. In FIG. 1, the circuit board would be vertical, for example, and soldered to the right side of the contact element. The corresponding side of the contact element would then be designed accordingly.

[0047] Furthermore, the connecting element 1 has a tulip contact 12, which is designed to receive the flat conductor 2 in an electrically conductive contacting manner. For this purpose, the tulip contact 12 has two clamping elements 121, 122 arranged next to each other and a support element 123. The flat conductor 2 can be inserted between the clamping elements 121, 122 and the support element 123. For this purpose, either the connecting element 1 can be pushed onto the flat conductor 2 in a sliding direction 92, or the flat conductor 2 can be pushed into the tulip contact 12 against the sliding direction 92.

[0048] Here, the tulip contact 12 is oriented at a substantially right mounting angle α with respect to the mounting surface 13. The sliding direction 92 therefore extends substantially transversely to the mounting surface 13, which is spanned by a first line (not shown) extending in a first direction of extension 91 transverse to the sliding direction 92, and by a second line (not shown) extending in a second direction of extension 93 transverse to the sliding direction 92 and transverse to the first direction of extension 91. In the mounted state, in which the flat conductor 2 is received in the tulip contact 12, the flat conductor 2 is clamped between the clamping elements 121, 122 and the support element 123.

[0049] In order to reliably prevent the connecting element 1 from detaching from the flat conductor 2, in particular also under vibration conditions, the clamping elements 121, 122 have latching devices 124, wherein the flat conductor 2 comprises mating latching devices 22 which cooperate with the latching devices 124. The latching devices 124 are formed in each case by a bend provided in the respective clamping element 121, 122. Elevations or projections are arranged on the flat conductor 2 as mating latching devices 22. In the assembled state, the bends 124 are arranged below the elevations 22 in the sliding direction 92, so that the connecting devices 1 cannot be displaced against the sliding direction 92. As a result, the connecting element 1 and the flat conductor 2 are not only clamped together in the assembled state, but also latched together, and detachment of the connecting element 1 from the flat conductor 2 is reliably prevented.

[0050] The support element 123 is arranged at a support end 111 of the mounting surface 13 thereon and extends from the mounting surface 13 to a free end 110. In the embodiment shown, it has a bend (not designated) with which it rests against the flat conductor 2 in the mounted state.

[0051] A connecting arm 14 is further arranged at a connecting end 112 of the mounting surface 13 facing away from the support element 123, which connecting arm 14 is provided for connecting the mounting surface 13 to the clamping elements 121, 122. The clamping elements 121, 122 are arranged at a contact end 113 of the connecting arm 14 opposite the connecting end 112. In this case, the connecting arm 14 engages over the support element 123, so that the clamping elements 121, 122 are arranged on a side (not designated) of the support element 123 facing away from the mounting surface. It is connected to the connecting arm 14 in an approximately arcuate manner. As a result, the clamping element is aligned at the mounting angle α with respect to the mounting surface 13 and is arranged in a resiliently yielding manner on the connecting arm 14. It is pivotable relative to the connecting arm 14 against a restoring force. The contact elements 121, 122 each extend to a free clamping end 114 which is bent away from the support element 123. This allows the flat conductor 2 to slide easily into the tulip contact 12 when the connecting element 1 is pushed on.

[0052] The connecting arm 14 has a substantially rectangular shape in cross-section. As a result, it has an outer surface 141 arranged approximately parallel to the mounting surface 13, which serves as a fastening device for an automation robot (not shown). This is a suction surface which enables the connecting element 1 to be gripped, so that the automation robot can mount the circuit board 3 with the connecting element 1 fully automatically in a terminal block 4.

[0053] The electrical circuit board 3 to which the connecting element 1 is attached is arranged in a recess 40 (see FIG. 2D) of a terminal block 4. A pin 42 is provided on an insulating material housing 41 of the terminal block 4, which serves as a stop for the circuit board 3. For this purpose, the pin 42 passes through a through-hole 31, which is arranged in the circuit board 3 and is provided as a counter stop. The pin 42 prevents relative movement of the circuit board 3 with respect to the insulating material housing 41 caused during mounting of the connecting element 1 on the flat conductor 2 and/or by the restoring force of the clamping elements 121, 122.

[0054] FIG. 2 shows in A-C in each case a section of the terminal block 4 with the circuit board 3, to which a connecting element 1 of a further embodiment is attached, in a perspective view, in 2D a housing shell 431 of the terminal block 4 in a perspective view, in 2E a circuit board 3 with a plurality of connection devices 1 attached to the circuit board 3 of the embodiment of FIGS. 2A-C in a perspective view, and in (f) the housing shell 431 of FIG. 2D when mounting the circuit board 3 of FIG. 2E.

[0055] The connecting element 1 differs from the connecting element 1 of FIG. 1 in the shape of the support element 123, which extends in a straight line at the mounting angle α, in particular at right angles, to the mounting surface 13. Furthermore, the flat conductor 2 arranged in the terminal block 4 differs from the flat conductor 2 of FIG. 1 by the mating latching device 22, which is formed here by an indentation in the form of a groove. In this embodiment, the latching device 124 of the clamping elements 121, 122, which are formed as a bend, latch in the groove. The flat conductor 2 is pressed flat against the support element 123 and thus also clamped.

[0056] On the circuit board 3 shown in FIG. 2E there are a number of connecting elements 1 offset and twisted relative to one another in the first and/or second direction of extension 91, 93. Each of the connecting elements 1 is associated with a stop in the form of a pin 42 which, when the circuit board 3 is mounted in the terminal block 4, is guided through the through-hole 31 corresponding thereto, thereby preventing relative movement of the circuit board 3 with respect to the insulating material housing 41 of the terminal block 4.

[0057] The terminal block 4 is shown in FIG. 2D. It has a housing 41 formed of insulating material in which a plurality of connecting devices 5 are arranged, each of which is provided for connecting an electrical conductor (not shown) to a busbar 2. A recess 40 is provided in the housing 41 to receive the circuit board 3. The busbars 2 each extend to the recess 40. Furthermore, a pin 42 is arranged in the recess 40 for each connecting element 1, or for each busbar 2, as a stop.

[0058] Furthermore, projections 61 are provided on the insulating material housing 41 for snapping the terminal block 4 onto a rail, in particular a hat-shaped rail (not shown).

[0059] FIG. 2F shows the mounting of the circuit board 3 in the recess 40 of the housing 41, with the circuit board 3 being pushed into the recess 40 in the sliding direction 92. In the process, the connecting elements 1 are each pushed onto one of the flat conductors 2 at the mounting angle α, so that the flat conductors 2 are each received in the tulip contact 12 of one of the connecting elements 1, and are clamped and/or latched between its support element 123 and its clamping elements 121, 122.

[0060] FIG. 3 shows a two-shell terminal block 4. The terminal block 4 has a first housing shell 431, shown in FIG. 3A, and a second housing shell 432, shown in FIG. 3B. The housing shells are formed to correspond to each other so that they can be mounted flush against each other. The housing shells 431, 432 mounted flush against each other, i.e. the fully assembled terminal block, are shown in FIG. 3 (d). In the exploded view of the terminal block 4 shown in FIG. 3 (c), it is visible that an insulating wall 433 is arranged between the two housing shells 431, 432.

[0061] It is visible that in each of the two housing shells 431, 432 several connection devices 5 are provided for connecting an electrical conductor. The connection devices 5 each have a busbar 2. Furthermore, each of the two housing shells 431, 432 has a recess 40 in which a circuit board 3 with the connecting elements 1 attached to it is mounted. Each of the connection devices 5, or each busbar 2, is assigned a connecting element 1. The circuit boards 3 are each mounted by sliding the connecting elements 1 onto the busbars 2 assigned to them. Here again, pins 42 associated with the connecting elements 1 are provided as stops, which are guided through through-holes 31 in the circuit board 3.

[0062] The circuit board 3 inserted in the first housing shell 431 is equipped with an electrical connection device 71, wherein the circuit board 3 inserted into the second housing shell 432 is equipped with a correspondingly designed counter-connecting device 72. The connecting device 71 and counter-connecting device 72 are provided for electrically connecting conductor tracks and/or conductive surfaces of the two circuit boards 3. They are placed in such a way that they make electrically conductive contact when the housing shells 431, 432 are joined together. To enable this, a breakout area (not shown) is provided in the insulating wall 433, which is broken out before the terminal block 4 is mounted.

[0063] FIG. 4A shows a section of the terminal block 4 of FIG. 3. The insulating wall 433 is not shown here.

[0064] Visible are connection devices 5.1, 5.2 arranged opposite each other, which are designed as spring-loaded terminals. They each have a clamping cage 51.1 in which a clamping spring 52.1, 52.2 is arranged, by means of which an electrical conductor inserted into the connecting device 5.1, 5.2 can be clamped to a busbar 2.1, 2.2 associated with the connecting device 5.1, 5.2 so as to make electrical contact with the latter. To release the electrical conductor from the connection device 5.1, 5.2, an actuating device 53.1, 53.2 is provided in each case, which actuates the clamping spring 52.1, 52.2 by displacement, so that the latter is displaced against its restoring force and clamping of the electrical conductor between the busbar 2.1, 2.2 and the clamping spring 52.1, 52.2 is released. Visible here is a connecting rail 20 which electrically conductively connects the two busbars 2.1, 2.2 of the adjacent connecting devices 5.1, 5.2.

[0065] FIG. 4B shows a housing shell 431 of a terminal block 4, which has projections 61 for snapping the terminal block 4 onto a rail (not shown). In this embodiment of the terminal block 4, one of the busbars 2 on which the circuit board 3 is mounted by a connecting element 1 is assigned to a functional earth contact 26 which is provided for grounding the rail.