CRIMPING ELEMENT AND METHOD FOR PRODUCING A CRIMPING ELEMENT

Abstract

The crimping element for holding a wire with a nominal diameter of approximately 0.1 mm or less comprises sheet-metal with a base portion extending in a base plane and a holding portion connected to the base portion. The holding portion comprises first and second clamping elements spaced apart from each other by a holding portion recess. The first element comprises a first clamping portion extending in a first plane and connected to the base portion and a second clamping portion, forming a first clamping region for holding the wire. The second element comprises a third clamping portion extending in a second plane and connected to the base portion and a fourth clamping portion, forming a second clamping region for holding the wire The first plane forms a first angle approximately 0°-10° with the base portion plane. The second plane forms a second angle approximately 1°-10° with the first plane.

Claims

1. A crimping element for holding a wire with a nominal diameter of approximately 0.1 mm or less, comprising: a sheet-metal element, comprising a base portion extending in a base plane and a holding portion connected to the base portion, wherein the holding portion comprises a first clamping element and a second clamping element, which is spaced apart from the first clamping element by a recess in the holding portion, wherein the first clamping element comprises a first clamping portion connected to the base portion, and a second clamping portion connected to the first clamping portion, and the first clamping portion and the second clamping portion form a first clamping region configured to hold the wire between the first clamping portion and the second clamping portion, wherein the second clamping element comprises a third clamping portion, which is connected to the base portion, and a fourth clamping portion, which is connected to the third clamping portion, and the third clamping portion and the fourth clamping portion form a second clamping region configured to hold the wire between the third clamping portion and the fourth clamping portion, wherein the first clamping portion of the first clamping element extends in a first plane, which forms a first angle in a range of approximately 0° to approximately 10° with the base plane of the base portion, and wherein the third clamping portion of the second clamping element extends in a second plane, which forms a second angle in a range of approximately 1° to approximately 10° with the first plane.

2. The crimping element as claimed in claim 1, wherein the second angle is in a range of approximately 2° to approximately 3°.

3. The crimping element as claimed in claim 1, wherein the first angle is approximately 0°.

4. The crimping element as claimed in claim 1, wherein the second clamping portion and the first clamping portion are bent toward one another about a first bending axis and the first bending axis extends substantially perpendicularly with respect to a direction of longitudinal extent of the recess.

5. The crimping element as claimed in claim 4, wherein the fourth clamping portion and the third clamping portion are bent toward one another about a second bending axis and the second bending axis extends substantially parallel to the first bending axis.

6. The crimping element as claimed in claim 5, further comprising: the wire with the nominal diameter of approximately 0.1 mm or less, wherein the wire is arranged in the first clamping region and the second clamping region that the wire extends along a direction of longitudinal extent of the wire, which extends substantially parallel to the first bending axis and substantially parallel to the second bending axis, in the first clamping region and in the second clamping region.

7. The crimping element as claimed in claim 1, wherein the holding portion comprises a third clamping element, which is spaced apart from the second clamping element by a further recess in the holding portion, wherein the third clamping element comprises a fifth clamping portion, which is connected to the base portion, and a sixth clamping portion, which is connected to the fifth clamping portion, and the fifth clamping portion and the sixth clamping portion form a third clamping region configured to hold the wire between the fifth clamping portion and the sixth clamping portion, wherein the fifth clamping portion of the third clamping element extends in a third plane, which substantially coincides with the first plane of the first clamping element.

8. The crimping element as claimed in claim 1, wherein the base portion also comprises contact elements, which are configured to make electrical and mechanical contact with an electrical printed circuit board.

9. A method for producing a crimping element for holding a wire with a nominal diameter of approximately 0.1 mm or less, wherein the crimping element comprises a sheet-metal element with a base portion extending in a base plane and a holding portion connected to the base portion, wherein the holding portion comprises a first clamping element and a second clamping element, which is spaced apart from the first clamping element by a recess in the holding portion, wherein the first clamping element comprises a first clamping portion connected to the base portion and a second clamping portion connected to the first clamping portion, and the second clamping element comprises a third clamping portion connected to the base portion and a fourth clamping portion connected to the third clamping portion, and the method comprises the steps of: bending the second clamping portion about a first bending axis so that the second clamping portion and the first clamping portion form a first clamping region configured to hold the wire; bending the fourth clamping portion about a second bending axis so that the fourth clamping portion and the third clamping portion form a second clamping region configured to hold the wire; and tilting the third clamping portion relative to the first clamping portion or tilting the first clamping portion relative to the third clamping portion so that the first clamping portion and the third clamping portion form an angle in relation to one another in a range of approximately 1° to approximately 10°.

10. The method as claimed in claim 9, wherein the third clamping portion is tilted relative to the first clamping portion or the first clamping portion is tilted relative to the third clamping portion so that the first clamping portion and the third clamping portion form the angle in relation to one another that is in a range of approximately 2° to approximately 3°.

11. The method as claimed in claim 9, wherein the third clamping portion is tilted relative to the first clamping portion or the first clamping portion is tilted relative to the third clamping portion before the second clamping portion is bent about the first bending axis and before the fourth clamping portion is bent about the second bending axis.

12. The crimping element as claimed in claim 2, wherein the second clamping portion and the first clamping portion are bent toward one another about a first bending axis and the first bending axis extends substantially perpendicularly with respect to a direction of longitudinal extent of the recess.

13. The crimping element as claimed in claim 2, wherein the first angle is approximately 0°.

14. The crimping element as claimed in claim 13, wherein the base portion also comprises contact elements, which are configured to make electrical and mechanical contact with an electrical printed circuit board.

15. The crimping element as claimed in claim 3, wherein the second clamping portion and the first clamping portion are bent toward one another about a first bending axis and the first bending axis extends substantially perpendicularly with respect to a direction of longitudinal extent of the recess.

16. The crimping element as claimed in claim 15, wherein the base portion also comprises contact elements, which are configured to make electrical and mechanical contact with an electrical printed circuit board.

17. The crimping element as claimed in claim 4, wherein the base portion also comprises contact elements, which are configured to make electrical and mechanical contact with an electrical printed circuit board.

18. The crimping element as claimed in claim 5, wherein the base portion also comprises contact elements, which are configured to make electrical and mechanical contact with an electrical printed circuit board.

19. The crimping element as claimed in claim 6, wherein the base portion also comprises contact elements, which are configured to make electrical and mechanical contact with an electrical printed circuit board.

20. The crimping element as claimed in claim 7, wherein the base portion also comprises contact elements, which are configured to make electrical and mechanical contact with an electrical printed circuit board.

Description

[0017] Further features and objects of the present invention will become apparent to a person skilled in the art by practicing the present teaching and taking into consideration the accompanying drawings. In the figures:

[0018] FIG. 1 shows a schematic view of a sheet-metal element with three clamping elements for producing one embodiment of a crimping element according to the invention,

[0019] FIG. 2 shows a schematic view of the sheet-metal element of FIG. 1, in which clamping portions of the clamping elements are bent, for producing one embodiment of a crimping element according to the invention,

[0020] FIG. 3 shows a schematic view of the sheet-metal element of FIG. 1 and FIG. 2, in which two clamping elements are tilted in relation to one another, for producing one embodiment of a crimping element according to the invention,

[0021] FIG. 4 shows a schematic side view of a crimping element not in accordance with the invention,

[0022] FIG. 5 shows a schematic side view of one embodiment of a crimping element according to the invention,

[0023] FIG. 6 shows a schematic side view of another embodiment of a crimping element according to the invention, and

[0024] FIG. 7 shows a schematic side view of another embodiment of a crimping element according to the invention.

[0025] Elements of identical design or function are provided with the same reference signs across all figures.

[0026] Reference is made firstly to FIG. 1, which shows a schematic view of a sheet-metal element 10 for producing a crimping element 12. The sheet-metal element 10, for example, has a thickness of 0.3 mm or less and has a base portion 14 and a holding portion 16 connected to the base portion 14. In the specific example of FIG. 1, the holding portion 16 has two substantially parallel slot-shaped recesses, which subdivide the holding portion 16 into three spaced apart clamping elements 18, 20 and 22. Specifically, the first clamping element 18 is spaced apart from the second clamping element 20 by a first recess 24. The second clamping element 20 is also spaced apart from the third clamping element 22 via a second recess 26. The recesses 24, 26 are substantially slot-shaped recesses, the first recess 24 extending along a first direction of longitudinal extent or axis 28 and the second recess 26 extending along a second, or further, direction of longitudinal extent 30, which is substantially parallel to and spaced apart from the first direction of longitudinal extent 28. The two slot-shaped recesses 24, 26 thus form tabs in the holding portion, which ultimately form the clamping elements 18, 20 and 22.

[0027] The clamping elements 18, 20 and 22 are also bendable or foldable along a bending axis 32. Thus, for example, the first clamping element 18 is bendable along a first bending axis 34, the second clamping element 20 is bendable along a second bending axis 36, and the third clamping element 22 is bendable along a third bending axis 38. In the specific example of FIG. 1, the first bending axis 34 extends substantially perpendicularly with respect to the first direction of longitudinal extent 28 of the first recess 24 and to the second direction of longitudinal extent 30 of the second recess 26. Similarly, in the specific example of FIG. 1, the second bending axis 36 and the third bending axis 38 each extend substantially perpendicularly with respect to the directions of longitudinal extent 28, 30 of the two recesses 24, 26. Moreover, in the specific example of FIG. 1, the first, second and third bending axes 34, 36 and 38 coincide to form a common bending axis 32, but may also run parallel to one another or obliquely with respect to one another, depending on the usage situation.

[0028] The first clamping element 18 also has a first clamping portion 40, which is connected to the base portion 14, and a second clamping portion 42, which is connected to the first clamping portion 40. The second clamping element 20 has a third clamping portion 44, which is connected to the base portion 14, and a fourth clamping portion 46, which is connected to the third clamping portion 44. The third clamping element 22 has a fifth clamping portion 48, which is connected to the base portion 14, and a sixth clamping portion 50, which is connected to the fifth clamping portion 48. The respective clamping portions of the respective clamping elements 18, 20, 22 are foldable or bendable toward one another along the respective bending axes 34, 36, 38, in order to form clamping regions for holding a wire, as will be described in more detail in conjunction with FIGS. 2 and 3.

[0029] As is also shown in FIG. 1, the base portion 14 has contact elements 52, which serve for making electrical and mechanical contact with an electrical printed circuit board (not shown). In the specific example of FIG. 1, the contact elements 52, for example, are in the form of plug-in projections for plugging into corresponding openings in the electrical printed circuit board. These plug-in projections, for example, may be electrically and mechanically connected to the electrical printed circuit board by means of soldering, by means of being pressed in, or by other means known to a person skilled in the art.

[0030] Reference will now be made to FIG. 2, which shows a schematic view of the sheet-metal element 10 of FIG. 1, the respective clamping portions of the respective clamping elements being bent toward one another about the respective bending axis in FIG. 2.

[0031] Specifically, the second clamping portion 42 and the first clamping portion 40 of the first clamping element 18 are bent toward one another about the first bending axis 34 in such a way that the first clamping portion 40 and the second clamping portion 42 form a first clamping region 54 between the first clamping portion 40 and the second clamping portion 42 for the purpose of holding a wire 56. Furthermore, the third clamping portion 44 and the fourth clamping portion 46 are bent toward one another about the second bending axis 36 in such a way that the third clamping portion 44 and the fourth clamping portion 46 form a second clamping region 58 between the third clamping portion 44 and the fourth clamping portion 46 for the purpose of holding the wire 56. Lastly, the fifth clamping portion 48 and the sixth clamping portion 50 are bent toward one another about the third bending axis 38 in such a way that the fifth clamping portion 48 and the sixth clamping portion 50 form a third clamping region 60 between the fifth clamping portion 48 and the sixth clamping portion 50 for the purpose of holding the wire 56.

[0032] In the specific example of FIG. 2, the wire 56 is an ultra-fine wire with a nominal diameter in a region of approximately 0.1 mm or less. Wires of this type, for example, are shape memory alloy wires, which are exposed to very frequent variations in loading and temperature and are used, for example, as actuators for valves in pneumatic adjusting devices for the pneumatic adjustment of a seat contact surface of a vehicle seat.

[0033] On account of the fact that the bending axes 34, 36, 38 are parallel to one another or coincide to form a common bending axis 32, and each of the bending axes 34, 36 and 38 extends substantially perpendicularly with respect to the directions of longitudinal extent 28, 30 of the two recesses 24, 26, it is possible to arrange the wire 56 in the clamping regions 54, 58 and 60 in such a way that a direction of longitudinal extent 61 of the wire 56 runs substantially parallel to the bending axes 34, 36 and 38.

[0034] Reference will now be made to FIG. 3, which shows a schematic view of the sheet-metal element 10 of FIGS. 1 and 2, two clamping elements or two clamping portions of the respective clamping elements being tilted in relation to one another in FIG. 3.

[0035] In the specific example of FIG. 3, the third clamping portion 44 of the second clamping element 20 is tilted by a predetermined angle relative to the first clamping portion 40 of the first clamping element 18. Similarly, the third clamping portion 44 of the second clamping element 20 is tilted by the predetermined angle relative to the fifth clamping portion 48 of the third clamping element 22. By contrast, however, the fifth clamping portion 48 of the third clamping element 22 is not tilted relative to the first clamping portion 40 of the first clamping element 18. This results in a substantially symmetrical arrangement of three adjacent clamping elements 18, 20, 22, it being the case in the specific example of FIG. 3 that the second clamping element 20, that is to say the middle clamping element, is tilted with respect to the two outer clamping elements 18, 22. The tilting of the middle clamping element 20 or the third clamping portion 44 relative to the first and the fifth clamping portion 40, 48 results in the wire 56 being twisted, so that the wire 56 is held particularly well and reliably in the clamping regions 54, 58 and 60. The crimping element 12 is thus distinguished by particularly reliable and secure holding of the wire 56.

[0036] In order ultimately to not subject the wire 56 to unnecessary loading or damage when it is being held in the crimping element 12, when the crimping element 12 is being produced first of all the third clamping portion 44 is tilted relative to the first clamping portion 40 and only then are the clamping portions 42, 46 and 50 bent about the respective bending axis 34, 36, 38. Such a sequence of the processing steps of the sheet-metal element 10 has the result that, when the third holding portion 44 is being tilted or when the second clamping element 20 is being tilted, the wire 56 is not yet completely fixed and the wire 56 can thus slip out, before, in the subsequent step, lastly the wire 56 is fixed in its offset and ultimate position by bending the clamping portions 42, 46 and 50. This selection or sequence of the processing steps of the sheet-metal element 10 largely avoids stretching or shearing of the wire 56 during the tilting operation, as a result of which the wire 56 is damaged less and the wire 56 thus has greater long-term stability.

[0037] In FIGS. 4 to 7 that now follow, a specific description will be given of the tilting of the clamping elements or clamping portions. For illustration purposes, first of all reference is made to FIG. 4, which shows a side view of a crimping element 200 not in accordance with the invention. In the crimping element 200 not in accordance with the invention, the clamping portions of the respective clamping elements are not tilted in relation to one another. The result of this is that, in FIG. 4 only one outer clamping element 202 can be seen and the further clamping elements, which lie behind the outer clamping element 202, have the same position in the side view of FIG. 4.

[0038] By contrast, FIG. 5 shows a side view of an exemplary embodiment of a crimping element 12 according to the invention, in which at least two clamping elements are tilted in relation to one another. In the side view of FIG. 5, this can be seen from the fact that the clamping elements 18, 20 or the first clamping portion 40 and the third clamping portion 44 have different positions in the side view of the crimping element 12.

[0039] In the specific example of FIG. 5, the base portion 14 extends in a base plane 62. Furthermore, the first clamping portion 40 of the first clamping element 18 extends in a first plane 64. In the specific example of FIG. 5, the first plane 64 coincides with the base plane 62, or the first plane 64 and the base plane 62 are parallel to one another. In other words, the first plane 64 and the base plane 62 form a first angle of approximately 0° in relation to one another. By contrast, however, the third clamping portion 44 of the second clamping element 20 extends in a second plane 66, which forms a second angle 68 that is not 0° with the first plane 64 in the specific example of FIG. 5. In the case of the crimping element 12 according to the invention, the second angle 68, in terms of magnitude, is in a range of approximately 1° to approximately 10°, preferably, in terms of magnitude, in a range of approximately 2° to approximately 3°.

[0040] A value of approximately 9° for the second angle 68 is obtained, for example, when the wire 56 has for example a spacing 70 of an order of magnitude of approximately 2 mm from an axis of rotation 72, about which the second clamping element 20 is rotated or tilted relative to the first clamping element 80, and moreover the third clamping portion 44 is tilted relative to the first clamping portion 40 by a thickness of 0.3 mm, which corresponds to the material thickness of the sheet-metal element 10, for example.

[0041] However, if the third clamping portion 44 is tilted much less, for example only by a nominal diameter of the wire 56, considerably smaller values result for the second angle 68. When the wire 56 has a nominal diameter of 0.076 mm, for example, and the third clamping portion 44 is tilted relative to the first clamping portion 40 only by the nominal diameter, given a spacing 70 of the order of magnitude of approximately 2 mm between the wire 56 and the axis of rotation 72 the result is a value for the second angle 68 of approximately 2°. Such a small tilt has the result that the wire 56 is not only held reliably, but at the same time the material stress that acts on the sheet-metal element 10 when the third clamping portion 44 is being tilted relative to the first clamping portion 40 is comparatively low. This increases the long-term stability of the wire 56.

[0042] Reference will now be made to FIG. 6, which shows another embodiment of the crimping element 12 according to the invention. In the exemplary embodiment shown in FIG. 6, it is also the case that the base portion 14 extends in a base plane 62, the first clamping portion 40 extends in a first plane 64, and the third clamping portion 44 extends in a second plane 66. As in the exemplary embodiment of FIG. 5, in the exemplary embodiment of FIG. 6 it is also the case that a first angle between the base plane 62 and the first plane 64 is approximately 0° and a second angle 68 between the second plane 66 and the first plane 64, in terms of magnitude, is approximately 1° to approximately 10°, preferably, in terms of magnitude, is in a range of approximately 2° to approximately 3°. However, in the exemplary embodiment of FIG. 6, the second clamping element 20 is tilted clockwise relative to the first clamping element 80, whereas in the exemplary embodiment of FIG. 5 the second clamping element 20 is tilted counterclockwise relative to the first clamping element 18. However, in both cases the second angle 68, in terms of magnitude, is in a range of approximately 1° to approximately 10°, preferably, in terms of magnitude, in a range of approximately 2° to approximately 3°. The embodiments of FIGS. 5 and 6 are intended to show that it does not matter whether the third clamping portion 44 is tilted clockwise or counterclockwise relative to the first clamping portion 40. What is important is that there is a tilt, and it is in the aforementioned angle range.

[0043] Reference will now be made to FIG. 7, which shows another embodiment of the crimping element 12 according to the invention. In the exemplary embodiment shown in FIG. 7, it is also the case that the base portion 14 extends in a base plane 62, the first clamping portion 40 extends in a first plane 64, and the third clamping portion 44 extends in a second plane 60. By contrast to the exemplary embodiments of FIGS. 5 and 6, however, the base plane 62 and the first plane 64 form a first angle 74 in a range which, in terms of magnitude, corresponds approximately to half of the range of the second angle 68. In other words: When, for example, the first plane 64 of the first clamping portion 40 and the second plane 66 of the third clamping portion 44 in turn form a second angle 68 which, in terms of magnitude, is in a range of approximately 1° to approximately 10°, preferably, in terms of magnitude, is in a range of approximately 2° to approximately 3°, a region of the first angle 74 is in a range, in terms of magnitude, of approximately 0.5° to approximately 5°, in particular approximately 1° to approximately 1.5°. In this configuration, moreover, when the first clamping portion 40 is tilted by the first angle 74 in a first, clockwise direction, and moreover the third clamping portion 44 is tilted in the counterclockwise direction (as illustrated by way of example in FIG. 7), a symmetrical arrangement is provided, which can hold the wire 56 particularly reliably. The exemplary embodiment of FIG. 7 is intended to show that it is entirely also possible for both the first clamping portion 40 to be tilted relative to the base portion 14 and for the third clamping portion 44 to be tilted relative to the first clamping portion 40 (and optionally also to the base portion 14).

[0044] Of course, other embodiments of the crimping element 12 according to the invention are conceivable. It is possible, for example, for the fifth clamping portion 50 to extend in a third plane that coincides with the first plane 64 of the first clamping portion 40. However, it is also conceivable for the fifth clamping portion 50 to extend in a third plane that does not coincide with the first plane 64, but forms a predetermined angle in relation to it. In all other respects, it is also conceivable for the third plane to likewise form a (identical or different) predetermined angle in relation to the second plane 66.

[0045] By virtue of the tilting of the clamping elements 18, 20, 22 or the clamping portions 40, 44, 48 in relation to one another, the crimping element 12 according to the invention ensures that the wire 56 is held reliably in the clamping regions 54, 58, 60 even in the event of frequent variations in loading and temperature. This is particularly advantageous for shape memory alloy wires, which are used as actuators for valves in pneumatic adjusting devices, since these wires are exposed to frequent variations in loading and temperature.

[0046] Although the crimping element 12 is shown in the form of an element consisting of three clamping elements 18, 20, 22 in conjunction with FIGS. 1 to 7, it is entirely conceivable for the crimping element 12, in other embodiments that are not shown, to have more or fewer than three clamping elements, but at least two clamping elements, that are tilted in relation to one another. Furthermore, in other exemplary embodiments of the crimping element 12 that are not shown, it is possible not only for the middle clamping element 20 to be tilted relative to the two outer clamping elements 18, 22, but it is also conceivable that one (or both) of the outer clamping elements 18, 22 is (or are, respectively) tilted relative to the middle clamping element 20.

[0047] In all other respects, it should be noted that FIGS. 1 to 7 are schematic drawings, and therefore specific values for the first or second angle should not be taken from the drawings. FIGS. 1 to 7 serve merely to illustrate the teaching disclosed in the present document.